Koenig & Bauer News Feed http://www.koenig-bauer.com/ en Koenig & Bauer AG Tue, 22 Jan 2019 18:43:07 +0100 Tue, 22 Jan 2019 18:43:07 +0100 news-1280 Wed, 16 Jan 2019 11:00:00 +0100 Tetra Pak to offer new levels of customisation and flexibility with digital printing technology https://iberica.koenig-bauer.com/en/news/detail/article/tetra-pak-to-offer-new-levels-of-customisation-and-flexibility-with-digital-printing-technology/
A first for the beverage carton industry, this investment taps the power of digital on-package printing to offer new possibilities for beverage brands  

Tetra Pak is to become the first company in the food and beverage carton industry to offer full-colour digital printing on its carton packages, working in collaboration with Koenig & Bauer AG, a global leader in the field.

The digital printing technology will simplify the complexity of design handling, reducing time from design to print and opening up new opportunities for flexibility in order placement and product customisation. Beverage brands can take advantage of added benefits like dynamic on-package printing and the ability to include a variety of designs within the same order.

Charles Brand, Executive Vice President, Product Management & Commercial Operations at Tetra Pak said, “We are committed to helping our customers explore new avenues with a truly ‘smart’ package, supporting their need for product customisation, smaller batch sizes, shorter delivery times, greater traceability and the ability to interact with the consumer. Our investment in this digital printer demonstrates our commitment to support customers with future-proof technologies as the digital revolution transforms the way we all do business.”

The full-width Koenig & Bauer RotaJET 168 digital printer is currently being built by Koenig & Bauer and will be installed at Tetra Pak’s converting plant at Denton, Texas. Field testing of the new, digitally-printed carton packages is expected to begin in early 2020 with North American customers.

Carmen Becker, President and CEO of Tetra Pak U.S. and Canada, said, “Brands continue to look for opportunities to deliver greater customisation and personalisation of their products. We’re thrilled to offer our customers new and innovative ways to engage with consumers, all while increasing flexibility in the design and order process.”

Christoph Müller, Member of the Board of Koenig & Bauer said, “We are absolutely delighted that Tetra Pak has decided in favour of our digital printer. Collaboration between our companies is on an extremely constructive and trusting basis. I am sure that, together, we will significantly change the market for the benefit of Tetra Pak customers.”

A sample 3D representation of the RotaJET 168 from Koenig & Bauer

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Digital printing References & Showcases
news-1277 Thu, 10 Jan 2019 08:08:29 +0100 Eight-colour Rapida 106 in operation in Marktheidenfeld since spring https://iberica.koenig-bauer.com/en/news/detail/article/eight-colour-rapida-106-in-operation-in-marktheidenfeld-since-spring/
  • High production output and minimal job changeover times
  • Focus on set-up times, availability and performance
  • LED-UV for ultra-short throughput times
  • Low waste thanks to intelligent job sequencing
  • Eight locations in Mainfranken and Saxony  
  • A Rapida 106 with eight printing units and perfecting for 4-over-4 production has been in operation at FLYERALARM at Druckhaus Mainfranken in Marktheidenfeld, near Wurzburg, since April 2018 .

    After extensive market evaluation, the high-speed press for printing speeds of up to 18,000 sheets per hour was ordered at the end of 2017. It is raised by 225mm and tailored exactly to the needs of the online printing service provider in terms of print spectrum and plate formats. All eight printing plates on the Rapida 106 are changed simultaneously in less than 40 seconds. DriveTronic SPC not only ensures fast plate changes but, together with CleanTronic Syncro, also the simultaneous washing of impression cylinders, blankets and rollers. It is also equipped with PlateIdent for extremely short job changeover times including register setting. The press not only offers high production outputs, but is also the perfect production tool for frequent and fast job changes, which are commonplace in the web-to-print business, a business driven by shorter runs, high quality and very short delivery times.

    December 2017: (l-r) Rolf Possekel, Koenig & Bauer (DE), Ulrich Stetter, managing director Druckhaus Mainfranken, Reinhard Marschall, managing director Koenig & Bauer (DE), and Christofer Hugel, Koenig & Bauer (DE), jointly sign the purchase contract for the eight-colour Rapida 106 (1)

    For print jobs ranging from 100 to approx. 5,000 sheets, the number of sheets printed in the first months of operation was relatively unspectacular. Nevertheless, FLYERALARM Industrial Print's management was impressed by how quickly the press achieved good performance figures after installation and how quickly the staff, a few of whom only had limited previous Rapida knowledge, got used to working with the new press. 9-10,000 plate changes per month, on the other hand, clearly show the market segment in which the Rapida 106 is at home and shows off its strengths. Job changes account for 60 to 70 percent of production time. “Makeready, makeready, makeready,” is how Ulrich Stetter, managing director of Druckhaus Mainfranken, describes his demands placed on the press. “Availability and performance,” adds Michael Deml, managing director of FLYERALARM Industrial Print.

    A year later: The Rapida 106 has been in operation at Druckhaus Mainfranken for more than half a year now. Ulrich Stetter (l), managing director of Druckhaus Mainfranken, and Michael Deml, managing director of FLYERALARM Industrial Print, here with Christofer Hugel (r), Koenig & Bauer (DE), are very satisfied with the new press (2)

    LED-UV printing for minimal production times

    What is more, the new press is equipped with the latest generation of LED UV dryers. The 4/4-colour printed sheets can be processed immediately when they come out of the machine. The need for storage space is eliminated, throughput times are slashed and customers receive their products faster. The significantly reduced use of powder in printing also reduces cleaning cycles on the finishing machines. FLYERALARM’s production specialists have many years of experience with UV printing in all its forms: from classic processes to HR and LED UV. They ensure that dry products are processed and delivered - without the need for any coating. There is no abrasion or set-off during transport.

    50 percent of production on the Rapida 106 is on uncoated and recycled paper. Other products include matt image papers, critical substrates and uncoated board. These are all demanding substrates that are in high demand on the market. Depending on the job and delivery time, production planning decides whether production is to be carried out using conventional or LED UV processes. Thanks to coordinated colour profiles, the company achieves almost identical print products regardless of process, press operator and weekday - even with repeat jobs using different processes.

    Despite all the automation: Press operator Karl-Josef Christ checks the register before starting the new job (3)

    Highly automated production

    Fast measurement and control technology monitors production. QualiTronic ColorControl measures and controls the ink densities on the front and back of the sheet. Intelligent job sequencing, depending on substrate and colour, also helps to shorten makeready times and reduce waste. The particularly small measuring strips (only 3mm high) allow the substrate area to be optimally used for marketable products. There is hardly any cutting waste. In addition, there are functions such as LiveView and inline register control. The Rapida 106 also features LogoTronic Professional production planning and control software with an integrated JDF interface for data exchange with MIS and prepress.

    Automatic ink supply frees up the operator from further routine tasks. Coated ink duct change plates (EasyClean) simplify the cleaning of the ink ducts should ink changes be necessary.

    Makeready, makeready, makeready: Karl-Josef Christ and Sofie Hetzer load the eight plate-loading cartridges with the printing plates for the next job (4)

    Printing in medium and large format

    Reduced workloads: fully automatic ink supply to the printing units (5)
    Medium-format systems are rather an exception in FLYERALARM’s production fleet. “Paper can be printed most efficiently with large-format eight-colour presses,” explains Ulrich Stetter.

    However: “If you look at the entire process, medium format offers clear advantages for some products.“ That’s why the Rapida 106 came into the company. Druckhaus Mainfranken now has the right technology for every product and can decide in the context of the overall process which format is most economical for production. For example, it can make sense to switch to B3 for complex finishing processes.

    Ulrich Stetter and Michael Deml are certain that Web-to-Print will continue to grow in the coming years. FLYERALARM, too, is showing signs of growth. This is achieved primarily through the expansion of its product portfolio to include cross-media products, new digital services and offerings in the field of advertising technology and promotional items. In addition, the online printing service provider invests in solid support during the purchasing process. FLYERALARM is one of the first to take on a product whenever it is necessary to produce small runs efficiently and particularly quickly.

    The eight-colour Rapida 106 is in operation day and night. Pile logistics can be added at a later date as the press is raised (6)

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    Sheetfed offset References & Showcases
    news-1265 Thu, 20 Dec 2018 11:28:26 +0100 Koenig & Bauer and Durst Phototechnik agree a 50/50 joint venture in digital printing https://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-and-durst-phototechnik-agree-a-5050-joint-venture-in-digital-printing/
    The modular concept of the VariJET combines the opportunities of digital inkjet with the acknowledged printing and inline finishing capabilities of the offset process for folding carton printing

    To further advance the development of future-oriented digital printing solutions with added value for customers in the folding carton and corrugated printing markets, Koenig & Bauer AG and Durst Phototechnik AG from Brixen/Italy have agreed to pool their know-how and strengths in a 50/50 joint venture. A corresponding letter of intent has been signed by both companies. The planned joint venture is to be based in Germany and – subject to merger control approval – will assume responsibility for the development, integration, manufacturing and worldwide distribution of water-based, single-pass digital printing presses for folding carton and corrugated board. Ink and service business relating to the presses sold jointly through the global networks of the two parent companies is also to be handled by the joint venture. As a first milestone for the joint venture, manufacturing of the VariJET press for digital folding carton printing is to be commenced in time for drupa 2020.

    Claus Bolza-Schünemann, CEO of Koenig & Bauer AG: “We are looking forward to joint innovations and further developments in future-oriented digital printing technology for folding carton and corrugated board, and not least to the added value this will offer to our customers. With its wealth of existing know-how, extensive inkjet experience and high-quality solutions, Durst Phototechnik AG is the ideal partner with whom to pursue the defined objectives. As digital printing pioneers, the company has been developing inkjet applications for 25 years and is very successful in digital printing on ceramics, textiles and corrugated board.”

    Christoph Gamper, CEO of Durst Phototechnik AG: “Durst is a technology leader in the field of inkjet printing and has already contributed to the digital transformation of production processes in various branches. In the printing industry and in surface decoration, in particular, Durst printing systems are deemed to set the standards with regard to print quality and productivity. The partnership with Koenig & Bauer now opens up new prospects, as Koenig & Bauer commands not only engineering expertise, but also very good access to the market. By combining our know-how, we are in an ideal position to develop and offer fully automatic production lines and will thus also be able to contribute to digital transformation in the folding carton and corrugated industry.”

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    Topic Market Company / IR Digital printing Technology Sheetfed offset Ideas & Innovation
    news-1263 Wed, 19 Dec 2018 12:37:59 +0100 Chinese packaging company orders sixth Rapida https://iberica.koenig-bauer.com/en/news/detail/article/chinese-packaging-company-orders-sixth-rapida/
  • Delivery in January 2019
  • Company has operated Koenig & Bauer sheetfed offset technology since 1997
  • Extensive process Automation
  • Hubei Guangcai Printing recently ordered a nine-colour Rapida 106 with coater and kit for UV mixed operation from Koenig & Bauer. It will be delivered to the company in Guangshui in the central Chinese province of Hubei in January and will go into operation in April. The press will mainly be used for the production of folding carton and cigarette packaging.

    L-r: Lianbao Wang, sales and marketing director at Koenig & Bauer in China, Xing Haifeng, general manager of Hubei Guangcai Printing Co., Ltd., and Dietmar Heyduck, senior vice-president sales Koenig & Bauer Sheetfed, after signing the contract for the delivery of a nine-colour Rapida 106

    Hubei Guangcai has been using Koenig & Bauer technology since 1997. Haifeng Xing, general manager of Hubei Guangcai explains: “In 1997 we actively expanded our operations in the field of cigarette packaging production. At that time it was imperative to import a state-of-the-art sheetfed offset press. We decided in favour of Koenig & Bauer after comparing and testing the various models on the market and conducting rigorous negotiations with the manufacturers. Koenig & Bauer‘s dynamic team and excellent service won us over. We opted for a five-colour Rapida 104 with coater. The Rapida 104 was the most popular press in Central China at the time.”

    Two sites, six Rapida presses

    Hubei Huawen is a wholly-owned subsidiary of Hubei Guangcai and the two companies have jointly purchased six Rapida sheetfed offset presses since the start of their cooperation with Koenig & Bauer. Hubei Guangcai has developed rapidly with its new technology. General manager Haifeng Xing remembers: “Our investment in Koenig & Bauer presses not only has increased production capacity, but has also driven technological innovation within our company. In line with market requirements, we have developed and introduced new technologies to protect our packaging against counterfeiting, e.g. by using special inks that react thermally or effect coatings that are difficult to copy. Our Rapida presses have allowed us to expand our cigarette packaging business.”

    The new Hubei Guangcai plant built in 2014 alone covers an area of more than 120 hectares. A high-end Rapida 106 with UV mixed operation joins two sheetfed offset presses at the site, a seven-colour Rapida 105 coater press and a six-colour Rapida 105 coater press (both with UV curing). The plant generates sales of around 260 million CNY (approx. €33m) annually. Like its predecessors, the nine-colour Rapida 106 is tailored precisely to Hubei Guangcai's needs for sustainable packaging production. Provisions have also been made for the future addition of a cold-foil module.

    High efficiency through comprehensive process automation

    The company intends to implement energy savings and improve its green credentials with more cost-effective cold-foil processes and the development of new finishing technologies. These measures, plus streamlining production, are essential for Hubei Guangcai to counter rising labour costs. Rapida presses offer every opportunity to boost production efficiency through comprehensive process automation.

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    Technology Sheetfed offset Topic Market References & Showcases
    news-1255 Sat, 01 Dec 2018 13:50:25 +0100 Koenig & Bauer and Duran Machinery unite to form Koenig & Bauer Duran https://iberica.koenig-bauer.com/en/news/detail/article/koenig-bauer-and-duran-machinery-unite-to-form-koenig-bauer-duran/
  • Duran Machinery, leading manufacturer of folder gluers becomes member of the Koenig & Bauer Group
  • Complete lines from printing to the processing of folding boxes from a single source
  • Duran’s brand OMEGA machines set new standards in the field of folding carton and corrugated gluing lines
  • Increase in market share and sales growth expected  
  • Koenig & Bauer has agreed with Duran Machinery in Istanbul to take over 80 per cent of its folder gluer business and integrate it into the Group under the name Koenig & Bauer Duran.

    With the acquisition of Duran Machinery Koenig & Bauer further expands its activities in the growing packaging market (from left to right): Christopher Kessler, legal counsel Koenig & Bauer; Patrick Masson, CEO of KBA-Iberica; Ralf Sammeck, CEO of Koenig & Bauer Sheetfed and member of the Koenig & Bauer management board; Oktay Duran, chairman of Duran Machinery; and Apo Kücükaras, Duran Machinery, after signing the contract

    With this latest acquisition, the world's oldest printing press manufacturer is once again strengthening its activities in the growth segment of machines and systems for packaging production. Together with the Rapida sheetfed presses from Koenig & Bauer Sheetfed, flatbed die cutters from Koenig & Bauer Iberica and the folder gluers from Duran, the company can now offer complete lines for the printing and processing folding boxes from a single source – with products made in Europe. This gives Duran a clear competitive advantage over other suppliers of folding box gluers, which are left to their own resources in this market segment.

    Ralf Sammeck, CEO of Koenig & Bauer Sheetfed and member of the Koenig & Bauer management board is pleased: "Over the past few years Duran has set new standards and successfully strengthened its position among our customers in the industrial packaging sector. We are now further expanding our worldwide presence as the printing press and die cutter manufacturer with the broadest product portfolio.“

    Duran has more than 30 years of experience in designing and manufacturing folder gluers in various formats and configurations. Thanks to market share gains, today Duran has established itself as one of the leading manufacturers in its field. Along with six standard series of Omega folder gluers with different specifications and ancillary equipment, the company also provides R&D services to meet specific production requirements, starting from unique packaging designs and the manufacturing of innovative tailor-made machinery. Duran machines are used worldwide by manufacturers of cardboard and corrugated board packaging in more than 65 countries. Koenig & Bauer Duran will proceed its activities in Duran Machinery’s existing premises in Istanbul and with Duran’s management fully on board.

    Oktay Duran, Chairman of Duran Machinery states: "We are proud to be a part of the great Koenig & Bauer Group and we are certain that we will achieve greater success in the global folding carton market with our new synergy.“

    Koenig & Bauer expects the acquisition and integration of Duran to boost its market share in folding carton gluers, strengthen packaging production activities and boost sales.

    The acquisition and integration of Duran is in line with the global Koenig & Bauer Group‘s strategy of focusing on growth markets. 

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    Sheetfed offset Flexo printing Digital printing Web offset Company / IR Market
    news-1162 Mon, 01 Oct 2018 11:21:16 +0200 From high-end webfed to digital services https://iberica.koenig-bauer.com/en/news/detail/article/from-high-end-webfed-to-digital-services/
  • Digital services
  • Augmented support
  • Market leader in newspaper presses    
  • Koenig & Bauer will be presenting its wide range of products and new service products on its 100m² stand in Hall 21a (No. E15) (1)

    As a technological pioneer, Koenig & Bauer will once again be presenting new, tailor-made and future-oriented solutions at this year’s IFRA World Publishing Expo (WPE) in Berlin. On a 100m²-large exhibition stand in hall 21a (No. E15), the market leader for medium and high-performance newspaper presses will present its broad product range from 9 to 11 October, as well as new service products for its own and third-party presses (through its subsidiary PHS) in the “Active Corner”. The need for press services has been rising continuously for years due to lower new press investments and the aging machine population. In addition to traditional Koenig & Bauer services such as retrofits, press relocations and upgrades, more and more customers are taking an interest in digital services. Koenig & Bauer offers a wide range of products from augmented support and MobileConsole to digital analysis of pneumatic systems. Koenig & Bauer is already developing artificial intelligence algorithms and optimization methods for proactive action. They can be used to identify patterns ensuring that unscheduled breakdowns can be detected at an early stage, avoided and necessary maintenance tasks can be planned. This pilot project will be presented to trade fair visitors through live demonstrations.

    MobileConsole - A tablet suitable for industrial use as a fully-fledged mobile console station with all operating functions. Operating and maintenance personnel can change or adjust settings on the press from any position (2)

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    Web offset Market
    news-1140 Tue, 25 Sep 2018 12:47:12 +0200 Artificial Intelligence in coding technology https://iberica.koenig-bauer.com/en/news/detail/article/artificial-intelligence-in-coding-technology/
  • Koenig & Bauer unveils Artificial Intelligence with Augmented Reality
  • “Kyana” is the voice of digitalisation in coding and marking
  • CorruCUT, CorruFLEX and CorruJET at FachPack
  • VariJET 106 – the future of the digital packaging market    
  • From corrugated board and folding box printing to invisible labelling for perfume flacons – visitors to FachPack, the European trade fair for packaging, processes and technology, from 25 to 27 September 2018 in Nuremberg, Germany, can experience the Koenig & Bauer Group's broad portfolio live. The joint stand manned by subsidiaries Koenig & Bauer Coding, Koenig & Bauer Sheetfed and Koenig & Bauer Digital & Webfed will present the latest trends in the growing packaging market.

    Two names are new: Koenig & Bauer Coding operated under the name KBA-Metronic until the middle of the year and is using the Group's new brand identity to introduce an internationally recognisable company name. Under the name Kyana, the company is also launching the first Artificial Intelligence system with an augmented reality application in coding printing. In future this technology will help to prevent operating errors, train staff and service technicians, and make processes more efficient. The foundations have been laid for further applications in other areas of Koenig & Bauer.

    Artificial Intelligence in coding printing – Kyana speaks to users

    Kyana, Koenig & Bauer AI, learns and communicates with the user (1)
    Kyana, the alphaJET’s artificial intelligence system, is an extremely effective 4.0 concept that goes far beyond previously known IoT (Internet of Things) applications, especially in B2B. Coding thus emphasises the Koenig & Bauer Group's role as digital trailblazer. The focus is on a valuable digitalisation concept that combines various advantages of the latest technologies in a logical way.

    Kyana learns permanently and adapts to various situations, gives advice on process optimisation and thinks one step ahead. The spotlight is on predictive maintenance, increasing availability and ensuring optimal production and printing processes. By means of a very human and simple manner of communication, Kyana supports the user and involves him proactively in a dialogue.

    The additional integration of Augmented Reality (AR) enables precise information transfer, both with regard to components and processes within the coding system. The use of virtual content enables a significant increase in production reliability. It also simplifies training and maintenance processes, and transcends distance or language barriers.  

    Kyana is the evolution to a robotic system and can adapt to individuals and their requirements in the identification process by means of language and AR. It thus sets new standards and demonstrates the immense opportunities of comprehensive digitalisation.

    The future of digital packaging printing: the VariJET 106 (4)

    The future of digital packaging printing and premium converting

    At FachPack, Koenig & Bauer Sheetfed will be focusing on the future of digital packaging printing with the VariJET 106. The press combines the advantages of digital inkjet printing with those of classic sheetfed offset, including high-quality inline finishing. In addition, trade fair visitors will receive information on superior packaging converting. Koenig & Bauer offers the Ipress series of flatbed die cutters (in 106 and 144 formats) and Optima 106 in various configurations. The Rapida RDC 106 rotary die cutter sets new standards in die cutting. It can produce up to 15,000 sheets per hour and features extremely short makeready times and high die-cutting accuracy. This makes it highly interesting for both long and short runs - as well as for packaging in the upper quality segment.

    The Rapida RDC 106 is characterised by its high die-cutting accuracy, outputs of up to 15,000 sheets per hour and extremely short makeready times (5)

    In addition to these highlights, the market leader in sheetfed offset presses for packaging printing is also providing information on the Rapida range from B2 to large format - with all the options and automation for high-quality and cost-effective production of folding carton, labels, carton and other packaging products.

    3D schematic of the high board line CorruCUT rotary die cutter from Koenig & Bauer (2)

    CorruCUT, CorruFLEX and CorruJET at FachPack

    The focus on growth markets such as conventional and digital packaging printing is part of Koenig & Bauer's successful strategy. By re-entering the market for corrugated board converting machines, the Group is consistently continuing along this path and is unveiling three new machines to customers at FachPack. The CorruJET is engineered for the efficient production of high-quality digitally printed corrugated board sheets. With the CorruCUT high board line rotary die cutter, a unique overall concept was created using state-of-the-art technologies and functions, combined with simple and intuitive operation. The CorruFLEX, designed in parallel, can be operated either as a stand-alone solution or in line with standard flatbed die cutters. It sets new benchmarks in terms of output and performance. 

    3D schematic of the new CorruJET from Koenig & Bauer (3)

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    Web offset Digital printing Sheetfed offset Flexo printing Market References & Showcases Ideas & Innovation
    news-1136 Thu, 20 Sep 2018 10:11:14 +0200 First league volleyball players ace photo shoot at Koenig & Bauer https://iberica.koenig-bauer.com/en/news/detail/article/first-league-volleyball-players-ace-photo-shoot-at-koenig-bauer/
  • Photo and video recordings for new season taken at printing press manufacturer
  • Two players nominated for World Cup in Japan
  • Club calendar printed by Koenig & Bauer Sheetfed  
  • On September 14, parts of Koenig & Bauer’s Radebeul plant were transformed into a volleyball arena. As part of their media day, the volleyball players of the first division club Dresdner Sportclub came to the Saxon printing press manufacturer. All the photos and videos for the new season were taken here - from various image and team photos to portrait photos of the players. They are used on the club’s website, in programmes, on posters, in the season magazine, for autograph cards and social media. Additionally, media representatives were given the opportunity to make their own recordings.

    Dirk Winkler, head of process engineering at Koenig & Bauer, among the successful volleyball players from Dresdner Sportclub

    Ralf Sammeck, CEO of Koenig & Bauer Sheetfed, and Dirk Winkler, head of process engineering and an enthusiastic volleyball player himself, have had contact with the club for years. They invited the players, two of whom have been nominated to take part in the World Cup in Japan, and their coaches to a photo shoot at Koenig & Bauer. The coveted calendars of the successful sportswomen have also been printed here for some years now.

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    Company / IR
    news-1132 Mon, 17 Sep 2018 13:18:36 +0200 L. N. Schaffrath commissions a long Rapida 106 perfector https://iberica.koenig-bauer.com/en/news/detail/article/l-n-schaffrath-commissions-a-long-rapida-106-perfector/
  • Open day welcoming active and former employees
  • New approaches in 4-over-4 production with additional coating
  • Automation and quality control at the highest level  
  • Modern location for a 275-year-old print and media house: L. N. Schaffrath possesses over 18,000 m² of production space and an extremely modern machinery pool (© Axel Breuer/plan b fotografie) (1)
    On 8 September, L. N. Schaffrath celebrated its 275th anniversary by inviting its active and all former employees, as well as the whole local community, to an open day at its production facility in Geldern. With a traditional “Gautschen” ceremony, a centuries-old custom marking the successful completion of a printer’s apprenticeship, tours of the printshop, the live presentation of a new eight-colour Rapida 106, a fascinating Schaffrath Printing Museum, the humanoid robot Pepper and many other activities for young and old, the company treated its guests to an interesting overview of modern media production in the 21st century.

    Technological flexibility

    Just a few weeks before the anniversary, the media house commissioned a new eight-colour Rapida 106 for 4-over-4 perfecting with additional coating. With this press, L. N. Schaffrath is treading new technological paths in its magazine production.

    On the one hand, the perfector press can print magazine covers in a single pass, including coating of the outsides. That already lends a significant boost to efficiency by eliminating the need for a second production pass, not to mention the otherwise necessary drying times. And secondly, the content pages which are typically a domain for web presses are also to be handled on the new sheetfed press for the first time.

    To this end, the Rapida 106 has been configured with an RS 106 reel sheeter, which is able to use the same reels as the webfed C16. Production can thus be switched between the two Koenig & Bauer presses at any time.

    The eight-colour Rapida 106 with perfecting and additional inline coating handles both cut sheets and reel stocks (2)

    Sheetfed printing of magazine content

    The diversity of magazines and catalogues on the market continues to increase. In addition, more and more titles are being produced in different editions and versions, in order to address individual target groups more directly.

    This is where the Rapida 106 is able to play out its strengths: Depending on the page count of the final product, sheetfed production can already be more profitable than use of a web press for run lengths from approx. 9,000 copies. Typical jobs from the 16-page web press can then be transferred to the Rapida 106, which is engineered for speeds up to 18,000 sheets per hour in perfecting mode. At L. N. Schaffrath, it now stands alongside a brand new MBO K8 RS folding machine, which itself fears no comparison with the lightning-fast Rapida 106 with production speeds of up to 275 m/min.

    The whole printer team with Bernd Susen (shift supervisor and sheetfed offset training instructor) and the press operators Vivian Saupe, Oliver Janssen, Klaus Richardson and Rainer Faets (left to right) is delighted with the highly automated Rapida 106. The first production came off the new press at the beginning of August (3)

    Fast, simultaneous makeready processes

    When it comes to automation and quality control, the Rapida 106 incorporates everything which is possible and also meaningful for an established media house: DriveTronic SPC with Plate Ident for simultaneous plate changing, CleanTronic Synchro for parallel washing processes, QualiTronic ColorControl for fast inline colour measurement and control, Lab colour measurement, ImageZoom (digital video magnifier), ErgoTronic ACR (video camera for register control) and extra-narrow colour bars. If it enables standardised production and makes work easier for the printers, then it is present on the Rapida 106.

    On 8 September, L. N. Schaffrath celebrated the 275th anniversary of the company at a grand open day, whose many highlights included a traditional “Gautschen” ceremony (4)
    A very high level of capacity utilisation is planned. “We expect to print around 50 million sheets per year on the Rapida 106,” says technical manager Martin Sellmann. The investment will thus be recouped in a relatively short time. Another new aspect is the gradual transition from a two-press set‑up to a single-press strategy in sheetfed offset. One press has already been dismantled, and the immediate predecessor of the Rapida 106 is to follow as soon as the new press reaches its full performance.

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    Sheetfed offset Market References & Showcases
    news-1128 Thu, 13 Sep 2018 14:10:21 +0200 Large Format meets LED-UV https://iberica.koenig-bauer.com/en/news/detail/article/large-format-meets-led-uv/
  • High-speed 4-over-4 printing using both reel stocks and piles on a Rapida 145
  • World premiere: LED-UV in large-format perfecting
  • Autonomous printing: 13 jobs in barely 70 minutes
  • Live info on important production parameters and performance indicators 
  • At the beginning of September, Koenig & Bauer placed large-format sheetfed offset in the spotlight again in Radebeul. The latest customer event left packaging printing to one side, however, and instead shifted the focus onto highly efficient commercial production, web-to-print and online applications. The press on show was an eight-colour Rapida 145 with perfecting unit for 4-over-4 production. The highlights of this press included LED-UV dryers to enable immediate further processing, as a world premiere in large-format perfecting, a large-format reel sheeter of the latest Quantum generation, the high production speed of 15,000 sheets/hour in perfecting mode, and the autonomous printing of multiple jobs and job sections with ErgoTronic AutoRun.

    Dirk Winkler, head of printing process technology at Koenig & Bauer in Radebeul, described the 13 print jobs in detail before the practical demonstration began (1)

    Dirk Winkler, head of printing process technology at Koenig & Bauer in Radebeul, took general and current demands of the print market such as fast makeready, low waste, ultimate quality and high outputs as the starting point for his presentation of automation solutions and unique features of the Rapida sheetfed offset presses specifically for the commercial and online market. These included the DriveTronic dedicated drive components which actually make simultaneous processes possible and thus contribute significantly to makeready reductions. The same can be said of the CleanTronic washing systems for optimised, parallel washing processes matched to each individual application. Fast, high-performance inline measuring and control systems (QualiTronic), a broad spectrum of VariDry dryers and end-to-end digital workflows are further key factors for extraordinarily cost-effective print processes.

    The reel sheeter in action at the maximum press speed of 15,000 sheets/hour (2)

    Benefits of LED-UV production

    Alongside general plus points such as fast further processing, improved print quality on uncoated papers, the elimination of odours and heat input into the substrate, waste and energy savings compared to other drying processes, reduced powder and coating consumption and less need for cleaning of the post-press machines, the LED-UV process offers further benefits particularly for perfector presses, for example:

    • Higher production speed
    • Elimination of the intermediate dryer tower which is otherwise necessary ahead of the perfecting unit
    • No danger of ink drying on the impression cylinders
    • No need for special ink-repellent jackets on the impression cylinders after perfecting
    • Minimised makeready times for frequent format changes
    • Optimum inline quality control as the QualiTronic ColorControl cameras can be placed in the ideal positions to scan both sides of the sheet  

    The eight-colour Rapida 145 in Radebeul was fitted with two LED-UV dryers, one above the storage drum of the perfecting unit and one in the swan neck of the delivery. It was also configured with a DriveTronic feeder, the sidelay-free infeed DriveTronic SIS, and simultaneous plate changing using DriveTronic SPC and Plate Ident. CleanTronic Synchro (including CleanTronic UV) provided for parallel and thus ultra-fast washing processes.

    Visitors to the special event in front of the demonstration press. A sheet from each of the 13 jobs can be seen on the gallery (3)

    Flying job changes in practice

    The print demonstrations began with the production of content pages for a magazine on 80 g/m2 paper. This paper was supplied on a reel and cut into sheets at the full production speed of 15,000 sheets per hour on the reel sheeter. Subsequently, the audience was able to witness fast conversion of the feeder for production using sheets from a pile, in preparation for printing of the magazine cover on 150 g/m2 glossy paper.

    The next jobs were three sections of a cookery book, for which the substrate was changed yet again to a 115 g/m2 matt paper. The job changes between the individual sections were realised fully automatically in an AutoRun process. As a result, only 1.5 minutes passed between the last good sheet of the old job and the first good sheet of the new job. These jobs were followed by another cover on 200 g/m2 glossy paper and two sections of a travel guide on 135 g/m2 glossy paper.

    Alexander Stern, workflow specialist and project manager, explained how press data come together in LogoTronic Professional and how all important economic indicators are determined (4)

    The presentation was rounded off with a series of five jobs typically handled by an online printer. The first three were corridor-free gang formes with flyers requiring run lengths of just 300 copies each. Again making use of the AutoRun function, production was here so fast that the helper on the press had his work cut out to remove the old plates from the plate changers and to insert the new ones in time for the next change. The jobs also switched back and forth between formes with high and low ink coverages, illustrating one of the particular strengths of an LED-UV process when printing gang formes. To conclude, two further gang formes with business and greeting cards were printed on 350 g/m2 board. For these jobs, the printer disengaged three inking units at the press of a button, enabling 4/1 production to proceed with any delay for roller washing and without the need to apply roller oil in the unused units.

    Immediately dry thanks to LED-UV: All the print samples were subjected to close scrutiny during the demonstrations (5)

    Live view of job data

    The print demonstrations were about more than just live print production on the Rapida 145, however. On external monitors, the visitors were able to follow how press data were gathered in the production planning system LogoTronic Professional and transferred to the management information system (MIS). The LogoTronic cockpit displayed all important production parameters, and it could be seen, for example, that the net production output was still 13,000 sheets/hour despite the many job changes. All makeready times were documented and the OEE (overall equipment effectiveness) was calculated and displayed. The Koenig & Bauer specialists explained the JDF/JMF workflow and use of the MIS Optimus Dash in daily commercial and online print production.

    Further presentations were devoted to data-driven Connected Services, Visual PressSupport and use of the Rapida LiveApps for decentralised press operation, maintenance, inventory management and consumables tracking.

    The conclusion reached at the event: Assuming a corresponding job pool, the Rapida 145 perfector is an ideal means of production for both long runs and jobs requiring only 250 sheets. The high production speed permits the efficient processing of long runs, while fast job changes with AutoRun enable extremely economical production when short runs are the order of the day.

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    Sheetfed offset Market