Service SelectRetrofits & upgrades

CleanTronic UV

The CleanTronic UV system permits considerable time savings by enabling the UV interdeck dryers to remain in standby mode during washing. With conventional UV lamps, the interlock delay times prescribed by industrial safety legislation cause production time to be lost for cooling and reheating at the beginning and end of each washing process. With CleanTronic UV, on the other hand, pivoted reflectors (shutters) contain the UV radiation and the lamp can be switched into a standby mode. When production is resumed, the shutter re-opens automatically and the lamp is available at production temperature immediately.

Scope:

  • Dryer control software update
  • Shutters for the UV interdeck dryers
  • Press software update
  • Installation, commissioning and training

Your benefits:

  • No waiting times for lamp cooling and warm-up
  • Time saving of up to 60% per washing cycle
  • Enhanced productivity and efficiency in UV and hybrid production

Time for installation:

  • Varies according to configuration

ErgoTronic ACR (Automatic Camera Register)

ErgoTronic ACR permits faster and more precise setting of the lateral, circumferential and diagonal register by calculating and transmitting the required setting values directly to the individual printing units. Both pre-registration and later corrections after production start-up are simplified for the operator. Register control is based on a camera system which is linked up to the press console. One separation is defined as the zero reference, and dots representing the remaining colours are evaluated accordingly to bring those colours into alignment. With up to 50x magnification, the camera can also be used to inspect freely selected areas of the image via the console monitor.

Scope:

  • Camera system for register control
  • Control computer
  • Press software update
  • Installation, commissioning and training

Your benefits:

  • More precise register setting
  • Faster makeready
  • Visualisation of register marks
  • Enhanced register accuracy

Time for installation:

  • 1 day

Flying Job Change

The possibility to set up a new job parallel to current production enables practically uninterrupted print production on a press with a corresponding number of printing units. The preparation for the new job is completed at makeready speed thanks to the dedicated (direct) drives of the units concerned. In the meantime, the remaining printing units continue production at full speed.

Scope:

  • Press software update
  • Installation, commissioning and training

Your benefits:

  • Faster makeready
  • More efficient utilisation of production time
  • Cost savings where frequent job changes are necessary

Time for installation:

  • Varies according to configuration

Plate Ident

 

A camera-based measuring system detects special register marks on the plates during automatic plate changing and calculates presetting values for the register systems of all relevant printing units. This ensures a very high register accuracy already before the first sheet is printed and thus accelerates the job changeover process. In addition to pre-registration, the system checks that the plates belong to the job in hand and that they are mounted on the correct printing unit, which means that it is no longer possible to start production with the wrong plates.

Scope:

  • New plate changer cassettes
  • Press software update
  • Installation, commissioning and training

Your benefits:

  • Reduced waste
  • Elimination of possible errors
  • Faster readiness for production

Time for installation:

  • 2 days

Plate correction program

 

When the program is started at the ErgoTronic console, the plate cylinder guards are opened and the plate cylinder is automatically positioned such that the correction screws of the rear plate clamps are directly accessible. That simplifies and accelerates the process of manual register corrections, and thus helps to save makeready time.

Scope:

  • Press software update 
  • Installation, commissioning and training

Your benefits:

  • Automatic cylinder positioning
  • Simplified press operation
  • Faster register adjustment
  • Faster makeready

Time for installation:

  • 0.5 days

Plate punches

Pneumatic and mechanical systems provide for the register-true punching of printing and coating plates with high repeat accuracy. Perfect matching to the register system on the plate cylinder ensures exact mounting and positioning of the printing plates on the press.

Scope:

  • Mechanical and pneumatic plate punches
  • Dual-purpose punches for printing and coating plates, if requested for all formats
  • Installation and commissioning  

Your benefits:

  • Precise punching to match the register system of the press
  • High repeat accuracy
  • Faster register adjustment
  • Less startup waste

Time for installation:

  • No installation required

Fast plate change

This software option enables the changing time to be shortened by up to 50% on presses with fully automatic plate changing (FAPC). This is achieved by increasing the press speed during the cylinder positioning and plate mounting phases.

Scope:

  • Press software update
  • Extension of the FAPC guards on all printing units
  • Installation, commissioning and training

Your benefits:

  • Up to 50% time saving per plate change
  • Faster and more efficient makeready
  • Time saving irrespective of the number of printing units

Time for installation:

  • 1 day

LogoTronic Professional

The production planning and control software KBA LogoTronic Professional serves to link production departments to a management information system as the basis for an unbroken JDF workflow. Whether the concern is overall production efficiency, benchmarking or JDF data exchange, KBA LogoTronic Professional closes communication gaps in the workflow, enhances the transparency of production processes and raises process reliability. You gain full control over the entire production chain and can at the same time reduce costs through exact post calculations and evaluations of a broad diversity of production data reports. 

Scope:

  • Software package
  • Press software update
  • Interfaces to branch software
  • Installation, commissioning and training
  • Optional: hardware

Your benefits:

  • Communication of press presetting data
  • Automated, real-time production data acquisition
  • Verification and tracking of production processes

Time for installation:

  • 3 days

LogoTronic Professional: Software update & hardware upgrade

 

The software and hardware components of an existing LogoTronic Professional installation are updated to the latest versions to guarantee the best possible support for your production planning and control. You gain access to the latest additional functions for the Rapida presses and secure optimum adaptation of the system to changing production demands. 

Scope:

  • Software update for your existing LogoTronic Professional
  • Hardware upgrade
  • Press software update
  • Installation and training

Your benefits:

  • Access to the latest versions of all key components
  • Cost-effective system update

Time for installation:

  • Varies according to configuration

QualiTronic

QualiTronic is a powerful measuring system for inline sheet inspection. It detects both transient blemishes (e.g. ink splashes, hickeys, paper defects) and more permanent deviations (e.g. scumming, fading ink supply, over-/under-inking). Any violation of defined tolerance limits is recognised at the earliest possible stage and immediately reported to the printer by a tab inserter. Targeted intervention is thus possible already before waste sheets are produced.

Scope:

  • Sheet inspection
  • QualiTronic inspection PC with separate desk
  • QualiTronic camera and illumination
  • Press software update
  • Installation, commissioning and training

Your benefits:

  • Additional possibility for automatic quality monitoring during production
  • Early detection of both transient and permanent defects
  • Less downtime for corrective measures to rectify deviations
  • Spectrometer (colour evaluation) and densitometer (ink film thickness) in a single system
  • Minimised costs for sorting of the sheets in post-press
  • Statistical evaluation functions

Time for installation:

  • 5-7 days

QualiTronic ColorControl

 

QualiTronic ColorControl is a system for inline ink density measurement and control on Rapida sheetfed offset presses. The camera system installed after the last printing or coating unit automatically determines the optical densities from printed colour bars. The measured values are then used as the basis for dynamic, inline control of the individual ink keys. On perfector presses, the ink densities can be controlled on both sides of the sheet.

Scope:

  • Inline density measurement and control
  • QualiTronic inspection PC with separate desk
  • QualiTronic camera and illumination
  • Press software update
  • Installation, commissioning and training

Your benefits:

  • Faster attainment of target colour
  • Faster makeready
  • Up to 30% less makeready waste
  • Measurements on both sides of the sheet when perfecting

Time for installation:

  • 5-7 days

QualiTronic Professional

 

QualiTronic Professional is a combination of the inline colour measuring system QualiTronic ColorControl and inline sheet inspection. The camera system is installed after the last printing or coating unit and permits full production monitoring right up to the maximum production speed, on the basis of a previously defined reference sheet. On perfector presses, print quality can be controlled on both sides of the sheet. Quality deviations are displayed on the console wallscreen or else signalled by way of a beacon above the press. Marking with a tag inserter and the printing of error reports are further possibilities.

Scope:

  • QualiTronic Professional inspection PC with separate desk
  • QualiTronic Professional camera and illumination
  • Press software update
  • Installation, commissioning and training

Your benefits:

  • Higher quality in the pile
  • Faster reaction to quality deviations
  • Reduced production waste
  • Colour control at production speed without the need to remove sheets from the delivery
  • Possibilities for use with inline coating and in perfecting

Time for installation:

  • 5-7 days

KBA Jackets

The combined effects of inks, substrate dust and process chemicals can lead to stubborn deposits on the rough-chrome surface of an impression cylinder – especially on perfector presses. Such contamination impairs production and print quality. Regular and intense cleaning is then necessary. The easy-to-clean KBA Jackets are fitted over the impression cylinder for lasting protection against both contamination and damage.

Scope:

  • Initial installation or replacement of worn KBA Jackets
  • Modification of the plate cylinder packing
  • Replacement of the gripper pads on the impression cylinders   

Your benefits:

  • Protection for the cylinder surface
  • Long-term preservation of the press value
  • Maximum print quality over the whole press lifetime
  • Improved production efficiency with high ink coverage
  • Durability of up to 50 - 70 million sheet output / press
  • Reduced waste thanks to three times less washing

Time for installation:

  • Varies according to configuration
 

Rider roller (dampening unit)

 

Where complex formes place high demands on the ink-water balance, the formation of an optimum dampening solution film is imperative to avoid quality impairments such as ghosting. The installation of an additional chrome rider roller under the dampening forme roller improves the balance between ink and water in the dampening unit. The risk of ghosting is minimized, print quality is enhanced and production waste is reduced.

Scope:

  • Chrome rider roller
  • Installation and commissioning   

Your benefits:

  • Enhanced print quality
  • Reduced waste
  • Time and cost savings thanks to faster makeready 

Time for installation:

  • 0.5 days

 

Lightweight package

 

The incorporation of various additional and replacement parts, especially in the area of the feeder, enables the trouble-free handling of substrates down to 30 g/m². With this accessory package, you can secure competitive advantages by broadening the spectrum of jobs which can be printed and thus appealing to new target groups. 

Scope:

  • Additional and replacement assortments
  • Installation of parts
  • Print instruction

Your benefits:

  • Substrate range extended to include thin materials
  • Broader product spectrum
  • Access to new target groups

Time for installation:

  • Varies according to configuration

Board handling package

 

Through the replacement or additional incorporation of specific press components, you extend your processing capabilities to embrace also heavier substrates such as microflute corrugated board. That opens up a whole range of new business opportunities, especially in the field of packaging printing.

Scope:

  • Additional and replacement parts
  • Installation and training

Your benefits:

  • Substrate range extended to include heavier materials
  • Competitive advantages thanks to a broader product spectrum
  • Access to new target groups, especially in the packaging segment

Time for installation:

  • Varies according to configuration

Hybrid package

Hybrid inks combine the properties of mineral-oil-based and UV-reactive ink systems. The fast curing of the inks and the reliable compatibility of the binder systems with UV coatings permit high-quality finishing with excellent high-gloss results in a cost-efficient inline process. The hybrid package offers you enhanced quality, cost-efficiency and ecological compatibility compared to the significantly more complex double-coating technology.

Scope:

  • UV interdeck and final dryers
  • 3-media washing system
  • Second coating circuit for UV coating
  • Automatic coating supply unit for UV and dispersion coatings
  • UV air extraction at delivery
  • Interface for UV dryers
  • Heat shielding and temperature monitoring for UV interdeck dryers
  • Additional blade chamber
  • Press software update
  • Installation, commissioning and print instruction

Your benefits:

  • Attractive possibilities for inline finishing
  • Broader product spectrum
  • Access to new target groups

Time for installation:

  • Varies according to configuration

Capacitive/optical double-sheet detectors

 

The retrofitting of capacitive and optical double-sheet detectors, as additions to the standard ultrasonic system, extends the range of substrates which can be printed (up to 1.2 mm thickness). The detection system can be activated manually or automatically, ensuring use of the most favourable sensor type for the current substrate. 

Scope:

  • Capacitive and optical double-sheet sensors
  • Installation and commissioning  

Your benefits:

  • Extended substrate range up to thickness 1.2 mm
  • Simple operation
  • Automatic switching between optical and capacitive detection
  • Greater production reliability and improved sheet travel

Time for installation:

  • 2 days

Board blower air

 

This option provides for smear-free sheet transport through the printing units when working with heavier boards up to 600 g/m². The continuous application of blower air ahead of the impression zone prevents the sheet from coming into contact with the blanket cylinder or other press parts. Even when running at full production speed, energy consumption is considerably lower than with timed air blasting.

Scope:

  • Blower bars in the printing units
  • Additional fan unit
  • Installation of parts and commissioning

Your benefits:

  • Extended substrate range
  • Substrate thickness up to 0.8 mm
  • Processing of substrates with flexural rigidity up to 150 Nm
  • Competitive advantages thanks to a more comprehensive product spectrum

Time for installation:

  • Varies according to configuration

Plastics package

Retrofitting of this accessory package enables the handling of a diversity of products based on plastics or similar substrates, such as bank and telephone cards, staff and customer cards, labels or packaging components, to name but a few examples. 

Scope:

  • Capacitive double-sheet detector
  • Polished and chrome-plated front lay covers
  • Special air-flushed guide rollers at the infeed
  • Antistatic systems for the feeder and delivery
  • Additional compressor for antistatic air at the feeder and infeed
  • Sheet travel sensors in each printing unit
  • Antistatic systems in the printing units (optional)
  • Board sheet guides
  • Delivery air extraction
  • UV dryers in accordance with the press configuration
  • Training

Your benefits:

  • Extended substrate range
  • Competitive advantages thanks to a broader product spectrum
  • Access to new target groups, especially in the packaging segment

Time for installation:

  • Varies according to configuration

VariDry UV dryer systems

VariDry UV is the key to a diversity of options for the high-quality finishing of print products. The use of UV inks and coatings, or likewise of hybrid inks, enables the printed sheets to be passed on for immediate finishing, as their surface is already completely dry. UV production also achieves very high levels of gloss.

Scope:

  • UV interdeck and final dryers
  • Second coating circuit for UV coating
  • Automatic coating supply unit for UV and dispersion coatings
  • UV air extraction
  • Interface for UV dryers
  • Heat shielding and temperature monitoring for UV interdeck dryers
  • Additional blade chamber
  • Press software update, if required
  • Installation, commissioning and print instruction

Your benefits:

  • Immediate further processing
  • Avoiding of waste due to ink which is not yet dry
  • High-quality gloss effects

Time for installation:

  • Varies according to configuration

Cold foil application: ColdFoil Infigo, Vinfoil Optima, Vinfoil Micro

 

In both commercial and packaging printing, customers are constantly looking for ways to lend their products an unmistakable and exclusive appearance. With a cold foil system, you are able to satisfy such market demands. The foil is applied efficiently and cost-effectively in an inline process. Compared to hot-foil stamping, for example, there is no need for expensive tools. 

Scope:

  • Installation of parts and commissioning
  • Training

Your benefits:

  • Modular system perfectly matched to KBA Rapida presses
  • Extremely fast foil changes save time with short runs
  • Digital layout and area calculations for optimum foil utilisation

Time for installation:

  • Varies according to configuration and chosen system

Slitter ICS

 

The slitting system ICS achieves considerable time savings, especially in short- to medium-run production. The slitting wheel is mounted in a precisely adjustable blade holder and runs on a steel band mounted on the impression cylinder. Two parallel piles are formed in the delivery. The additional process step of cutting on a separate guillotine is saved.

Scope:

  • Installation of parts and commissioning
  • Training

Your benefits:

  • Time saving through elimination of an additional process step
  • Inline finishing solution
  • Saving of separate post-press equipment

Time for installation:

  • 4 days

Reel sheeter RS 106

 

The reel sheeter RS 106 is an inline module which enables the efficient use of reel stocks on a high-speed sheetfed press. It can be incorporated into KBA Rapida 105 and 106 sheetfed presses. The use of reel stocks offers numerous benefits in terms of cost savings, process stability and material utilisation. A space of approx. 5 metres is required in front of the feeder for installation.

Scope:

  • Installation and commissioning of reel sheeter
  • Training  

Your benefits:

  • Savings potential of 14-20% when using reel stocks instead of pre-cut sheets
  • Improved sheet travel thanks to the minimised risk of double and skew sheets
  • Cutting to an individual sheet length avoids trimming waste
  • Utilisation of leftover reel stubs from web-fed production
  • High running speeds with thin or coated papers and with other demanding substrates

Time for installation:

  • Varies according to configuration

Non-stop pallets

The use of standardised KBA non-stop pallets guarantees a smooth pile changing process at the feeder. The pallet channels into which the fingers of the non-stop rake are inserted during pile changing are matched to the standardised finger spacing. It is highly recommended to use such dedicated pallets also for manual non-stop pile changing, in order to guarantee a trouble-free sheetfed and -delivery.

Scope:

  • Non-stop pallets

Your benefits:

  • Pallet design matched to the spacing of the non-stop rake fingers
  • Smooth pile changes in non-stop operation
  • Eliminates canting when using non-compatible pallets

Time for installation:

  • No installation required

Innovative & competitive – Attractive upgrades keep you up-to-date

Technology development cycles are today shorter than ever before, and changes sometimes arrive faster than you were hoping. Your current equipment was the latest state of the art just a while ago, but a successor model is already coming into the news. If your press is no longer deemed up-to-date, you run the risk of losing out to a competitor with a more modern alternative.

Saving and expansion opportunities

Expand and upgrade your sheetfed offset press with additional, profit-enhancing features. Our experts would be glad to advise you on the possibilities and can calculate your expected return on investment. Based on the setup of your company and your specific press configuration, we can together explore the savings potential and identify scope for meaningful expansion. 

Brochure KBA Sheetfed Service
Download PDF, 6 MB
  • Faster makeready and less waste
  • Further improved print quality
  • Increased cost efficiency
  • Expansion of your production portfolio and greater flexibility to accommodate customer wishes, e.g. a broader spectrum of possible substrates or finishing technologies
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