Rapida 105

Feeder and infeed

DriveTronic feeder

  • Feeder motions controlled via 4 servomotors
  • Continuous, stepless pile lifting with automatic speed compensation (paper/board)
  • Antistatic rear-edge separating air
  • Automatic format setting
  • Automatic pile side edge alignment
  • Front-edge pile height sensing with automatic compensation of the feeder head height
  • Skew-sheet correction at the feeder head during production

Suction-belt feed table

  • Suction-belt feed table with stainless, antistatic structured surface and multichamber vacuum system
  • Electronically controlled sheet deceleration to ensure optimum sheet arrival speed at the front lays

Vacuum side lay

  • Marking-free alignment process
  • Multi-chamber vacuum system to permit matching to different substrates
  • Included in automatic format setting

Infeed

  • Central parallel and skew adjustment of the feed line
  • Central adjustment of the front lay cover height
  • Touchscreen display with direct function keys for reliable and intuitive press operation

Sheet monitoring

  • Ultrasonic double-sheet detector, also for inhomogeneous materials
  • Multiple-sheet detector
  • Optical skew-sheet and side lay sensors
  • Optical front lay sensors with electropneumatic overshoot blocking
  • Magnetic crash bar

Non-stop operation at the feeder

  • Non-stop system with individual rods for uninterrupted production during pile changes
  • Pile insertion and removal possible from all three sides

Printing unit

Design principles

  • Unit design
  • Double-size impression cylinders and transfer systems for reliable sheet travel over the full substrate range
  • 7 o‘clock cylinder arrangement
  • Substructure cast in a single piece for high torsional rigidity and stability
  • Continuous gear train for smooth running and precision
  • Corrosion-free cylinder surface finish
  • Bearer contact and play-free bearings for precise rolling between plate and blanket cylinders
  • Central lubrication

Sheet travel

  • Gentle, air-cushioned sheet travel with blower systems and Venturi guide plates
  • Automatic setting of the substrate thickness
  • Pneumatic impression on/off switching

Universal gripper system

  • No adjustments required to accommodate changes in substrate thickness
  • Coated gripper tips and structured gripper pads for maximum holding force
  • Gripper pads and tips can be replaced individually
  • Increased gripper shaft diameter

Register setting

  • Remote setting of lateral, circumferential and diagonal register
  • Diagonal register achieved by tilting the transfer drums
  • ErgoTronic ACR for automatic and exact register checking and correction

Inking unit

ColorTronic ink duct

  • Ink keys with carbide blades and ceramic-coated ink duct roller
  • Remote control of the ink keys
  • Wear-free ink metering ensures accurately reproducible settings
  • Ink duct roller speed compensated to the press speed

Ink duct foil

  • No influence on the basic ink duct setup, as the foil does not extend into the metering gap
  • Convenient ink removal and cleaning reduces makeready time
  • Fast and uncomplicated foil replacement

Inking unit

  • New, fast-reacting inking unit
  • Remote setting of vibrator frequency and blocking from the control console
  • Ink train separation with impression-off
  • Automatic adjustment of the oscillation timing from the control console
  • Ink forme roller oscillation
  • Inking unit temperature control for duct roller and oscillating distributors
  • Individual engaging/disengaging of inking units from the console for reduced roller wear and minimised makeready times

Dampening unit

  • New, speed-compensated Varidamp film-type dampening unit for a stable ink-water balance
  • Skewing of the dampening duct roller to adapt dampening solution distribution across the press width
  • Differential drive to eliminate hickeys, activated from the control console during production

Plate change

QAPC (Quick Action Plate Change):

Simple plate change

  • Plate change with quick-release clamps
  • Automatic plate cylinder positioning
  • Pneumatic plate clamping
  • Divided rear plate clamps

SAPC (Semi Automatic Plate Change):

Automated plate change

  • Pneumatic opening and closing of the plate cylinder guard
  • Automatic rotation to the change positions
  • Automatic clamping and tensioning of the plate
  • Divided rear plate clamps

FAPC (Fully Automatic Plate Change):

Fully automatic plate change

  • Automatic plate change on the whole press after program start at the control console
  • Parallel changing in several printing units, completed in 3 cycles
  • Faster, optimised change process with change time of 2.8 min, including register zeroing
  • Divided rear plate clamps

Washing systems

CleanTronic roller washing

  • Individual programming and central control of washing programs

CleanTronic blanket and impression cylinder washing

  • Simple washing beam for blanket washing (with Easy Set)
  • Swing-action washing beam for combined blanket and impression cylinder washing
  • Individual programming and central control of washing programs
  • Parallel washing of rollers and blanket
  • Use of dry cloth or ready-impregnated cloth rolls
  • Indication of washing cloth consumption at the control console

CleanTronic Multi

  • Multiple-media washing system permitting the use of different ink systems

"Print clean" function

  • Targeted stripping of the remaining ink from plate and blanket
  • Reduced blanket washing times and material consumption
  • Enhanced production stability with thin materials
  • Pre-selection of the number of sheets to be used
  • Can replace blanket washing for short runs

CleanTronic UV

  • Safety function to eliminate waiting times before and after cylinder washing when printing with UV inks
  • More efficient makeready and longer service life for UV lamps

Coater

Chamber blade system

  • Hydropneumatic control for constant and even coating application
  • Lightweight anilox rollers ensuring fast and user-friendly replacement

Coating supply system

  • Coating supply system for dispersion and UV coatings in separate circuits
  • Central control via the press console
  • Fully automatic cleaning for dispersion and UV coatings
  • Excellent cleaning result enabling immediate use of the coating system for the next job

Coating forme change

  • Universal clamps for blankets and coating plates
  • Quick-release clamps for coating plates with register system for automated forme change (change time: approx. 1 min)
  • Remote pressure setting
  • Remote adjustment of lateral and circumferential register from the press console

Delivery

Sheet travel

  • High-level delivery for smooth sheet transport
  • Touchscreen display with direct function keys for reliable and intuitive press operation
  • Air-cushioned sheet guiding with multiple Venturi systems
  • Speed-compensated gripper opening cam for a broad range of substrates
  • Fan modules and blower bars promote optimum pile formation
  • Standard-compliant light barriers to guard the hazardous area

Powder sprayer

  • Speed-compensated and format dependent powder metering

Sheet brake

  • Sheet brake with pre-suction plate and variable speed to facilitate precise sheet delivery
  • Suction rings can be deactivated in pairs

Extraction system

  • Elimination of health hazards from ozone and VOC emissions

Extended delivery

  • Extension length 2,400 mm
  • Enhanced productivity when coating thanks to shorter drying times

Non-stop operation at the delivery

  • Non-stop pile change possible at full production speed
  • Lowerable non-stop roller rack extended automatically above the main pile
  • Sensor monitoring for lifting/lowering of main and auxiliary piles
  • Alternative: Non-stop system without lowering capability for smaller pile heights or several product piles on a single pallet

Drying systems

VariDry IR/hot air

  • IR/hot-air drying with stepless control
  • Can be installed as final dryers, as intermediate dryers or in a dryer tower
  • Carbon twin lamps with IR power rating of 60 W/cm
  • Lamp replacement without tools
  • Dryer control on the basis of pile temperature

VariDryBlue

  • System variant for enhanced energy efficiency
  • Energy saving potential up to 50% compared to conventional IR/hot-air dryers
  • Unsaturated dryer air recirculated within the extended delivery
  • Controlled via the press console

VariDry UV

  • Compact dryer module with UV power rating of 160 W/cm (stepless control)
  • Can be installed as final or interdeck dryers
  • Lamp replacement without tools
  • Automatic pile temperature measurement
  • Lamp-specific acquisition of operating hours, irrespective of installation position
  • CleanTronic UV to shorten the waiting times when washing

Console and workflow management

ErgoTronic

  • Touchscreen for ergonomic access to all press functions
  • Wall screen for visualisation of all press settings
  • Live image from QualiTronic ColorControl on wall screen
  • ColorTronic ink metering with ink profile displays on console
  • Integration with existing DensiTronic Professional possible
  • Linear densitometer ColorDrive and ErgoTronic ACR possible
  • Sheet inspection desk with adjustable desk angle
  • Motorised console height adjustment with memory function
  • USB port for fast communication of job data
  • Uninterruptible power supply to enable controlled press shutdown in case of power supply failure
  • Integrated remote maintenance module KBA PressSupport 24Sheetfed with Internet link for remote maintenance and software updates

Control console functions (dependent on incorporated options)

  • Job changeover program JobAccess for automatic job presetting
  • Job-specific saving of all relevant press parameters for repeat jobs
  • Remote register setting
  • Integration of "Instrument Flight" for extended colour control according to grey balance
  • Control for all peripheral equipment
  • Maintenance indicator and print-outs of maintenance lists
  • Unbroken production data acquisition in conjunction with LogoTronic Professional
  • Creation and printing of pile dockets
  • Preview images  

Job changeover program JobAccess

  • Preparation of the next job while production is still running
  • Automatic execution of all preselected makeready processes in time-optimised order
  • Presetting of format and substrate thickness
  • Presetting of all substrate-specific air settings
  • Job-specific presetting of ColorTronic ink metering
  • Preselection and activation of washing functions

LogoTronic

  • Ink profile presetting via CIP3 data

LogoTronic Professional

Comprehensive management system for KBA presses:

  • CIP3/CIP4 interface to prepress
  • JDF/JMF interface to an MIS
  • Order management
  • Press presetting
  • Master data, including central ink database
  • PressWatch for graphic representation of the overall production process
  • SpeedWatch for graphic representation of job progress
  • Automatic saving and management of all quality reports

Remote diagnosis and maintenance

Remote maintenance

  • Integrated remote maintenance module in every press
  • Most comprehensive remote maintenance functionality and longest experience on the market
  • Access to individual printing unit controllers possible
  • Fast assistance and problem remedies in up to 80% of all cases – without need for service visit or spare parts
  • Telephone hotline free of charge during the warranty period
  • Immense time and cost savings
  • Increased availability of the press

Spare parts service

  • Comprehensive product and quality tests for original KBA parts
  • Competent and efficient advice from our service specialists
  • Guarantee of outstanding precision and quality, high reliability and maximum service life
  • Spare parts incorporating the latest state of the art
  • High availability of over 2.5 million parts
  • Fastest possible delivery of spare and accessory parts

Retrofits

  • Adaptation of already installed presses to changing market conditions
  • Possibilities to shorten makeready times, reduce waste or further improve quality
  • Considerable experience gained in the course of many successful modernisation projects
  • Comprehensive measures to raise press productivity possible

Technical details

Sheet format: 

 

Maximum (standard/special version)

720 x 1,050 / 740 x 1,050 mm

Minimum (standard/special version)

360 x 520 / 350 x 500 mm

Minimum for perfecting 

400 x 480 mm 

Print format: 

 

Standard/special version

710 x 1,040 / 730 x 1,040 mm

Maximum for perfecting 

700 x 1,040 mm 

Substrates: 1): 

 

Standard

0.06 - 0.7 mm

Perfector press

0.06 - 0.6 mm

with lightweight equipment

0.04 mm

with board-handling

1.2 mm

with corrugated equipment

1.6 mm

Production speed: 2) 

 

Maximum, depending on configuration (speed-enhancement package)

16,000 (17,000) sheets/h

Production speed: 2) with perfecting unit: 

 

up to 10 units in straight printing

15,000 sheets/h

up to 10 units in perfecting mode

14,000 sheets/h

Pile height 3):

Feeder

1,300 mm

Delivery

1,200 mm

Plate and blanket dimensions: 

 

Plate size

795 x 1,050 mm

Copy line (standard/special version)

50 / 36 mm

Blanket size

860 x 1,060 mm

 

1) Printability is also influenced decisively by the flexural rigidity of the substrate
2) Dependent on individual processing parameters, e.g. the inks and substrates used
3) From floor / without non-stop operation 

Productvideos: Rapida 105

  • Rapida 105 - Product information
  • Rapida 105 - Rapida 106 inside
  • Rapida 105 - The new perfector

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