Rapida 106

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

• 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

• 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 

• 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 

• 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

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

• 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

• 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

• 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 

• 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 with change time of 2.8 min, 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

• 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

• Multiple-media washing system permitting the use of different ink systems
• Available for CleanTronic and CleanTronic Synchro

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

• 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

• 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  

VariDry^Blue

• 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

• 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

• 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

• 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:

• Sheet inspection desk as vacuum board with fixed desk angle
• ErgoTronic ColorControl for density and Lab measurements
• ErgoTronic ICR for register control

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