Rapida 106

Feeder and infeed

DriveTronic feeder

  • Feeder motions controlled via 4 servo motors
  • Continuous, stepless pile lifting with automatic speed compensation (paper / board)
  • 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
  • Antistatic loosening and separating air

Suction-belt feed table

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

Infeed

  • Swing infeed accelerates the sheet smoothly for transfer to the feed drum
  • Motorised remote adjustment with DriveTronic Infeed for front lays, feed line and front lay cover height
  • Photoelectric infeed sensors with motorised setting from the control console or infeed display
  • Touchscreen display with direct function keys for reliable and intuitive press operation

DriveTronic SIS (Sensoric Infeed System)

  • Patented KBA sheet infeed system
  • Electronically controlled lateral sheet alignment
  • Integration into automatic format setting eliminates all need for operator intervention
  • Gentle sheet positioning with the highest possible accuracy
  • Patented Venturi system before the feed line for smooth sheet infeed
  • Pneumatic drive elements for precise positioning of the sheet, even at maximum speed
  • Pile side edge alignment via the SIS sensor

Sheet monitoring

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

Non-stop operation at the feeder

  • Manual non-stop system with individual rods for uninterrupted production during pile changes
  • Fully automatic non-stop system with sensor-monitored rake, suitable for pile logistics integration
  • Sensor monitoring for pile transportand pile reunion
  • Pile insertion possible from all three sides 

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

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

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
  • Oscillating rider on the dampening duct roller
  • Differential drive to eliminate hickeys, activated from the control console during production
  • Dampening solution preparation with digital temperature control and display 


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 to prevent slapping against the blanket cylinder and Venturi guide plates under the transfer drums
  • Air settings can be set and saved at the ErgoTronic console for repeat jobs
  • Automatic setting of the substrate thickness
  • Two-stage 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
  • Wider outer grippers to avoid critical sheet overhangs 

Register setting

  • Mechatronic remote setting of lateral, circumferential and diagonal register from the ErgoTronic console
  • Diagonal register achieved by tilting the transfer drums
  • ErgoTronic ACR (Automatic Camera Register) for automatic measurement and control based on individual sheets via a separate video magnifier
  • ErgoTronic ICR (Integrated Camera Register) for fully automatic register control on the sheet inspection desk
  • QualiTronic ICR for fully automatic register control in the press

Perfecting

Design principles

  • Proven three-drum configuration for exact perfecting register
  • Special perfecting drum gripper system handling a broad substrate range
  • Fully automatic conversion between straight and perfecting mode in approx. 2 minutes

Sheet guiding after perfecting

  • KBA Jackets on the impression cylinders
  • Anti-marking coat on the drum shells
  • Sheet guide plates can be removed individually without tools
  • Gentle, air-cushioned sheet travel with blower systems and Venturi guide plates under the transfer drums
  • Twisting suckers spread the rear edge of the sheet tight on the storage drum
  • Air settings made at the ErgoTronic console can be saved and recalled for repeat jobs
  • Sheet travel sensor
  • Video system to observe sheet travel below the perfecting drum and in the delivery
  • Optical missing sheet sensor

Coater

Coater tower

  • Chamber blade coating system with laser-engraved anilox roller
  • Remote pressure setting
  • Remote setting of lateral, circumferential and diagonal register
  • Quick-release clamps with register system for coating plates
  • Lightweight anilox rollers for fast and convenient roller exchange 

Chamber blade system

  • Hydropneumatic chamber control for constant and even coating application
  • HydroComp blade pressure control ensures maximum blade life 

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
  • Intelligent Viscosity Logic (IVL) for coating level control and viscositydependent pump control
  • Heating for UV coatings
  • Specialty Circulation Kit for metallic coatings and other special applications

Automated coating forme change

  • Automated coating forme change with change time approx. 1 min

DriveTronic SFC (Simultaneous Forme Change)

  • Automated coating forme change
  • Coating forme change parallel to other makeready processes on the printing unit

KBA AniloxLoader

  • Facility for fully automatic anilox roller exchange
  • Magazine above the coater tower as intermediate storage
  • Exchange process runs simultaneously with other makeready processes
  • Integrated into the job changeover program

Dryer system

VariDry IR/hot-air

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

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 dryers or in a dryer tower
  • Lamp replacement without tools
  • Automatic pile temperature regulation and dryer control
  • Lamp-specific acquisition of operating hours, irrespective of installation position
  • CleanTronic UV to shorten waiting times when washing

VariDry HR-UV

  • Highly reactive UV system with specially doped lamps
  • Stepless adjustment of the lamp power between 80 and 200 W/cm
  • Suitable for conventional and highly reactive UV inks
  • HR-UV dryers can be used in all available installation positions, also in combinations of HR-UV and conventional UV

Delivery

Sheet travel

  • High-level delivery for smooth sheet transport
  • Touchscreen display with direct function keys for reliable and intuitive press operation
  • Venturi sheet guiding system, with all air settings made and saved at the console
  • Shadow-free aerodynamic gripper systems to accommodate radiation dryers
  • Speed-compensated gripper opening cam for a broad range of substrates
  • Fan modules and blower bars with directional air flow promote optimum pile formation; with remote adjustment
  • Standard-compliant light barriers to guard the hazardous area 

Powder sprayer

  • High-performance powder sprayer with antistatic blower air and remote control from the console
  • Speed-compensated and formatdependent powder metering

Sheet brake

  • Dynamic sheet brake with speedcompensated suction belts for smooth and precise pile formation
  • Maximum utilisation of the sheet format when printing on the reverse
  • Automatic format adjustment
  • Deactivation of individual suction modules from the console
  • Substrate-dependent control of suction power
  • “Easy-click” replacement of suction modules

Emission Extraction System EES

  • Extraction system to eliminate health hazards from ozone and VOC emissions

Extended delivery

  • Extension modules for dryer installations
  • Enhanced productivity when coating thanks to longer time for drying

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


Logistic

Non-stop operation at the feeder

  • Non-stop system with individual rods for uninterrupted production during pile changes
  • Fully automatic non-stop system with sensor-monitored rake for pile transport and pile reunion
  • Pile insertion and removal possible from all three sides

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 

PileTronic

  • Networking of press control, nonstop pile changing systems and pallet supply for efficient print production
  • Proven logistics modules
  • Elaboration of customer-specific solutions
  • Pallet-free paper supply possible


Console

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 ErgoTronic 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

ErgoTronic with integrated measuring systems

In addition to the standard ErgoTronic features:

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
  • 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
  • Automatic execution of all preselected makeready processes in time-optimised order

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

 

 

Technical data

Sheet format

 

Maximum (straight/perfecting)

740 x 1,060 / 740 x 1,060 mm

Special format (straight)

750 x 1,060 mm

Minimum (straight/perfecting)

340 x 480 / 400 x 480 mm 


Print format

 

Maximum (straight/perfecting)

730 x 1,050 mm / 720 x 1,050 mm

Special format (straight)

740 x 1,050 mm


Substrates 1)

 

Standard

0.04 – 0.7 mm

With board-handling package (from approx. 450 g/m²)

up to 1.2 mm

With courrugated package

up to 1.6 mm

Perfector press

up to 0.7 mm

Perfector press with board-handling package

up to 0.8 mm

Gripper margin

10 mm


Production speed2)

 

Up to 9 printing units + coater or 10 printing units 

18,000 sheets/h  

With high-speed package (option)

20,000 sheets/h

Perfector press up to 10 printing units in straight mode

18,000 sheets/h 

Prefector press up to 10 printing units in perfecting mode

15,000 sheets/h 

With high-speed package (option)

18,000 sheets/h


Pile heights from floor


Feeder

1,250 mm

Delivery

1,200 mm

Feeder in non-stop operation

1,000 mm

Delivery in non-stop operation

1,100 mm


Plate and blanket dimensions


Plate size

795 x 1060 mm

Copy line (standard)

36 mm

Blanket size

860 x 1070 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

Plate change

SAPC (Semi Automatic 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)

  • 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, including register zeroing
  • Divided rear plate clamps


DriveTronic SPC (Simultaneous Plate Change)

  • Simultaneous, fully automatic plate change in all printing units
  • Plate cylinder direct drive with dedicated high-torque motors
  • Plate change parallel to other makeready processes on the press, e.g. blanket washing; effective makeready time thus 0 seconds


FJC (Flying JobChange)

  • “Flying job changes” in a matter of seconds
  • DriveTronic SPC and DriveTronic Plate Ident permit fully automatic plate changes during on-going production
  • Automatic cleaning of the blanket with “print clean” function
  • Especially recommendable for short runs with frequently changing language versions


DriveTronic Plate Ident

  • System for register presetting and plate identification directly on the press
  • Sensors on the plate holder detect additional register marks
  • Register presetting values are calculated individually for all printing units
  • Automatic implementation of the necessary corrections on the press
  • Reading of a data matrix code verifies the presence of the correct plate for the current job
  • Faster makeready as register adjustment already occurs during fully automatic plate changing

Washing systems

CleanTronic washing systems

  • Multi-purpose washing system for ink rollers, blanket and impression cylinder
  • Swing-action washing beam for combined blanket and impression cylinder washing
  • Parallel washing of rollers and blanket
  • Serial washing of blanket and impression cylinder
  • Individual programming and central control of washing programs
  • Use of dry cloth or ready-impregnated cloth rolls
  • Indication of washing cloth consumption at the control console

CleanTronic Synchro

  • Separate washing beams for blanket and impression cylinder washing
  • Parallel washing of blanket and impression cylinder
  • Parallel washing of rollers and blanket

CleanTronic Multi

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

“Print clean” function

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

Productvideos: Rapida 106

  • Rapida 106 - Flying JobChange
  • Pile logistics - Introduction
  • Pile Logistics - Prerequisites
  • Pile Logistics - Logistics systems
  • Pile Logistics - Practical examples
  • Rapida 106 - Product information

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