Compacta 215
New developments in press engineering such as individual shaftless drives, distributed intelligent controls, paper-saving minigaps on plate and blanket cylinders and an automatically convertible gripper folder make the KBA Compacta 215 the most advanced 16-page commercial web offset press of its class on the market.
Compacta 215 two-level press
- KBA DriveTronic shaftless drives for fast changeovers and greater flexibility
- Minigaps on plate and blanket cylinders for high print quality and reduced paper waste
- Automatically convertible F3 gripper folder with choice of modules to support product diversity
- Cantilevered turner bars and former for easy access and fast webbing-up
- Two control consoles for easy handling and less legwork
- Wide choice of configurations from simple straight-on press to two-level press
- Automation modules to enhance productivity, (automatic plate changing, web infeed, KBA Patras A reel logistics, digital link to pre-press via CIP3 interface, KBA LogoTronic multilevel production management system)
Distributed controls and shaftless drives
Our module-based KBA Patras system allows reel logistics for commercial web presses to be custom-configured to suit individual production requirements and printshop architecture.
KBA Patras
- Wide choice of models for commercial web presses ranging from Patras M with manual loading to high-automation Patras A with reel stripping and KBA Easy Splice automatic splice preparation
- Configuration customised to suit production requirements and available space
- Patras A embeds paper logistics in a networked production process, delivering substantial savings in time, waste and production costs
KBA Patras feeding two commercial web presses
KBA Easy Splice
KBA Easy Splice
- Automatic splice preparation unit
- Handles up to 15 reels per hour
- Reduces operator workload and enhances safety during automatic reel change
KBA Pastomat C
- KBA Pastomat C beltless reelstand driven and braked via reel core by robust AC servo motors
- Reelstand arms infinitely adjustable by remote control for different reel widths
- Fully embedded in press control system
- Maximum web speed 12 mps (2,362 fpm)
- Maximum reel weight 1,800 kg (3,967 lbs)
- Maximum reel width 1,000 mm (39½ in)
The prime objectives in developing the printing units for the Compacta 215 were to ease operation and reduce maintenance work while maximising print quality and the range of printable stock.
Printing unit with plate changing (26158)
- Shaftless drives
- Paper-saving minigaps on plate and blanket cylinders
- Zero-play multi-ring bearings
- Printing pressure adjustable to stock thickness
- Quality-enhancig film inking units
- Dampening unit for alcohol-free printing
- Automatic plate changing
- New imprinter system with dedicated drives
Printing unit with film inking unit
Minigap
Our engineers drew heavily on their gravure expertise for the Compacta 215's new-design superstructure. All essential elements such as turner bars, former and RTFs are cantilevered for easy access.
Compacta 215 superstructure
- Extensive range of configurations to suit individual production requirements
- Cantilevered turner bars
- Key draw units driven directly by 3-phase AC motors
- Slitters operate like scissors
- New system for trimming web on both sides
- Linear register rollers afford optimum control of cut-off register
Superstructure with one web, straight-on production
Superstructure with one web through turner bars; F3 with 2 x 8pp module
Production flexibility, short makereadies, high folding accuracy, low maintenance, absolute reliability and easy operation - these were the targets set in developing the F3 gripper folder for the Compacta 215.
Automatically convertible F3 gripper folder
- Grippers exploit minigaps' paper-saving potential
- Standard version includes first cross fold, double parallel fold, delta fold, quarter fold, timed length perforation and on-the-run depth adjustment of cross perforation
- Automatic adjustment for different types of production
- Dedicated drives
- Systems not required for a particular job can be disconnected to save energy
- On-the-run circumferential adjustment of spider wheel enhances quality of copy stream delivery
- Severer ensures that inrunning ribbon cannot jam
- No paper dust deposits in gripper-cylinder jaws
- Stop in quarter fold can be cleaned of trimmings during production
- Double parallel fold and delta fold can be dispensed with
F3 gripper folder
F3 gripper folder with a complete set of modules
The user-oriented control console KBA ErgoTronic, the automatic presspresetting system KBA EasyTronic and the production management system KBA LogoTronic are important elements of an integrated automation concept.
Through the networking of intelligent control technologies at unit level, the operating crew maintains full control over the whole press throughout all phases of production. With KBA OPERA (Open Ergonomic Automation System), KBA furnishes the modules which are indispensable to master today's increasingly complex press installations and the instant dialogue between man and machine which these demand.
KBA EasyTronic
The automatic press presetting system KBA EasyTronic raises the availability of the press and contributes to considerable savings in wastage. It features, for example, automated web-threading, automatic web width conversion when setting up a new job, run-out washing in accordance with production demands, and defined preinking. All superstructure and folder components are preset on the basis of the pre-press data. A single press of a button provides for optimised starting, setting-up and stopping of the press, ensuring the shortest possible production times and an absolute minimum of wastage.
LogoTronic basic
All KBA Compacta presses are equipped as standard with the LogoTronic basic version of the system. This version serves to transfer essential preset data to the press. LogoTronic basic embraces the optional modules CIPLink (CIP3/CIP4 data transfer for press presetting) and logging for paper and ink data. The existing company hardware (server) is used to implement the networking system. Presetting data for the ink keys and for the duct roller settings are transferred.
LogoTronic professional
To support a digital exchange of job and presetting data for the press, to permit immediate monitoring and systematic evaluation of production data, and to establish links to upstream PPS systems or company EDP networks, the console can be further expanded by adding the open production management system LogoTronic professional. The logging of press and production data facilitates operations management, with KBA LogoTronic as a source of truly meaningful statistics. LogoTronic professional is the central element of communication between KBA presses and the corresponding print company MIS, whether via direct database access or via JDF. The communication module JDFLink implements JDF data exchange.
PressWatch
The LogoTronic component PressWatch provides management with an overview of all the jobs currently being run. Counter states, printing speeds, job data and progress, press status messages and a whole array of other relevant information can be displayed in real time.
SpeedWatch
SpeedWatch creates a time/speed diagram, similarly in real time, with which all events and messages for a selected press can be depicted. Correspondingly authorised persons are able to access this information via the Internet or the company Intranet.
JDFLink with LogoTronic professional
Interconnection of LogoTronic professional via the universal interface JDFLink offers the following advantages:
- Unbroken automated workflow (job data can be passed directly from the branch
- Access to LogoTronic professional from all connected workstations
- Presetting and repeat data provide for shorter makeready times
- More effective production per shift
- Less waste
- Single data input brings greater efficiency and reduces the risk of errors
- Improved cost accounting on the basis of exact press and production data (no daily worksheets to be completed by hand)
- Clearer overview through facility to retrieve all job, presetting and press data
- Comprehensive and transparent information for management
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Cylinder circumference
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546 - 620 mm (21.5 - 24.5 in) (other circumferences on request) |
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Minimum web width |
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420 mm (16.5 in) |
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Maximum web width |
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1,000 mm (39.5 in) |
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Maximum rated output |
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50,000 cph |
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Standard stock weights |
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36 - 130 gsm (24 - 120 lbs book), with sheeter 200 gsm (110 lbs index) |
Basic equipment
- Reelstand
- Infeed unit
- Stretching roller
- Printing units
- Blanket-washing unit
- Ink feed system
- Dampening-water system
- Web catcher
- Dryer with/without afterburner
- Chill roller stand
- Superstructure
- Silicone unit
- Web-centre alignment
- Colour register control
- Cut-off register control
- Length gluing
- Automatically convertible F3 gripper folder (basic module)
- Plate-punching machine
- Bending machine
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OPERA
- Console (KBA ErgoTronic) with electrical angle adjustment
- Remote adjustment of inking unit, dampening unit and register (KBA ColorTronic)
- Shaftless drive technology (KBA DriveTronic)
- Production management system (KBA LogoTronic Basic)
- Console (KBA ErgoTronic) with electrical angle adjustment
- Remote adjustment of inking unit, dampening unit and register (KBA ColorTronic)
- Shaftless drive technology (KBA DriveTronic)
- Production management system (KBA LogoTronic Basic)
Optional equipment
- KBA Patras reel handling system
- Webbing-up unit
- Imprinter
- Automatic plate changer
- Desk illumination
- Height adjustment for desk
- Remoistening unit
- Cross lead for parallel press
- Steel substructure for two-high press
- Auxiliary former
- F3 extension module for 2 x 8 or 2 x 16 pages
- F3 extension module for cutter
- Cutter and perforator
- Coater and gummer
- Plough fold
- Compressed-air unit
- Chilling unit
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OPERA
- Film and plate scanner (KBA ScanTronic)
- Production management system (KBA LogoTronic Professional)
- Online data transmission (KBA CIPLink)
- Film and plate scanner (KBA ScanTronic)
- Production management system (KBA LogoTronic Professional)
- Online data transmission (KBA CIPLink)