Commander CT 4/2

Our range of compact presses has now been expanded beyond the waterless Cortina to include the Commander CT (= compact), a wet offset press that delivers a raft of benefits over conventional tower or satellite presses. Standing just 4.5m (14ft 9in) high, the Commander CT represents a major advance in ergonomics, cost efficiency, flexibility and quality, enabling newspaper and semi-commercial printers to respond with agility to evolving market demands. No sooner had it launched on the market than the Daily News, a New York publishing house, placed a major order for this highly automated press. 

KBA Competence: conventional or waterless 

The Commander CT represents a conventional alternative to the Cortina for printers who are unwilling to go waterless at this point in time, for example because of restrictions imposed by existing equipment when extending conventional press lines, or reservations concerning the use of unaccustomed consumables. User-focused as ever, we now offer a choice of processes to suit your individual preferences. Both presses incorporate the exceptionally high level of automation that typifies the KBA Competence compact platform.  

Proven automation 

The Commander CT and the Cortina are the only two newspaper presses in the global marketplace to feature StepIN towers that split down the centre at the touch of a button for easy access and maintenance. Convenient lifts on both sides of the towers reduce walking distances. Other features common to both press types are our fast yet highly reliable KBA PlateTronic automatic plate changers, revolutionary KBA NipTronic cylinder bearings with optional remote adjustment of the printing pressure, and KBA RollerTronic automatic roller locks, which have proven their efficiency a thousand times over and in terms of functionality and precision are far superior to other automatic locks. 

The only difference between the Cortina and Commander CT is in the printing process: the Cortina is both keyless and waterless, whereas the Commander CT has optimised spray dampeners and film inking units with ink keys and three forme rollers. The double-circumference Commander CT is available as a doublewidth (4/2) or triple-width (6/2) version engineered for full colour on both sides of the web, with the option of printing 2/2 on two webs. 

The prototype of the compact Commander CT was honed to market maturity at the Main-Post in Würzburg and successfully embedded in the daily production routine. In summer 2008 the existing four-high tower was expanded into an eight-high one – a space-saving configuration that is only possible with the Cortina or Commander CT – and at the beginning of 2010 will have two more towers added. A further Commander CT press line has since gone live in Spain, and in autumn 2009 the New York Daily News will press the button on a major 6/2 installation comprising a grand total of 15 four-high towers. If you are looking for highly innovative yet mature technology, and the agility to address future market demand by combining newspaper and semi-commercial production, then the Cortina or Commander CT is your ideal choice.  

For decades offset printers have dreamt of being able to set the nip pressure automatically, precisely and with no time-consuming manual adjustment. Now we have made this possible with our revolutionary NipTronic cylinder bearing unit which even, as an option, allows the optimum printing pressure for different stock thicknesses to be set automatically to predefined reference values from the console. Along with RollerTronic automated roller locks, which incorporate components and know-how from the automotive industry, NipTronic is a groundbreaking KBA innovation that delivers real benefits for users in terms of print quality and the range of stock that can be handled. 

KBA NipTronic: precise pressure – precise dot 

Up until now the nip between the plate, blanket and impression cylinders, even on modern offset presses, has generally been set manually, either using cams or by changing the packing under the blankets to adjust the distance between the cylinders. This takes a lot of time – and time being money, press operators tend to avoid it if at all possible. The result? A high dot gain, poor quality solids when changing from coated to uncoated stock, a shorter plate life and worn blankets. 

The NipTronic bearing unit comprises a proven conventional cylinder bearing seated in play-free, pretensioned linear guides which permit movement on just one plane. There is no need for multiring bearings, cams or bearer rings. The precise printing pressure is set to predefined reference values and the plate and blanket cylinders thrown on electrohydraulically, after which the bearing is locked against a setting wedge. At impression OFF the system is released and maintenance-free springs return the bearing to its original position. The compact, integrated system operates in an oiltight housing. The printing unit side frames are oil-free. 

The plate and blanket cylinders can be thrown on and off individually or collectively. The optimum nip pressure between the plate and blanket cylinders and between the two blanket cylinders in blanket-to-blanket presses can also be set remotely for individual cylinders or for all the cylinders collectively. In addition it is possible to set and adjust optimum printing pressure fast when running blankets with different spring characteristics or after prolonged blanket use, and to set printing pressure precisely following changes in stock type. 

The four cylinders in a blanket-to-blanket printing unit are aligned at a slight incline, with the NipTronic bearing units screwed onto the side frame tight against the cylinder body. It has been found that this minimises vibrationrelated streaking, even when working with wide webs. 

Other benefits include a longer bearing, plate and blanket life, a lower energy consumption, less maintenance and increased resistance to wrap-ups. 

KBA RollerTronic: proven a thousand times over 

KBA RollerTronic roller locks, which set the inking and dampening rollers in the Commander CT by defining their throwon pressure, are far more accurate and efficient than mechanical systems that define the distance to be travelled. What is more, the rollers in each section can be set automatically either individually or collectively in a matter of minutes, eliminating the need for time-consuming and universally unpopular manual roller adjustment. Throw-on pressure is set according to predefined reference values and the rollers then locked mechanically. Not only is this much more precise and delivers a more uniform print quality; it also reduces roller abrasion, energy consumption and maintenance input. 

The control electronics and automation systems for the Commander CT are engineered to the same standard of excellence as the rest of the press to maximise output and flexibility, minimise waste and manning levels, optimise image quality in full-colour production and support integration into an alldigital workflow. 

Even the basic version of our high-tech Commander CT features an extensive, module-based automation package that affords enormous flexibility in accommodating individual production specifications. ErgoTronic consoles with easy-read, easy-learn data screens are a standard feature. The interfaces to the master systems for press preset, process control, production monitoring and dedicated software are clearly defined. For press extensions and more specialised customer applications we offer the option of installing console technology supplied by other manufacturers such as ABB or EAE. 

The electronic processing stations for press controls and drive systems are located in the reelstand arms, printing units, folder and other subassemblies. They are connected to each other and to the console by high-powered data bus systems. 

The current operating status of the press, and any malfunctions which may occur, are displayed immediately at the console and remedial action initiated automatically if the need arises. The clear, logical system facilitates press operation and monitoring and affords greater flexibility when extending or modifying the press line. 

Copy- and press-based operation 

Even the basic version of our Commander CT includes a valuable operator aid in the form of a copy-based system which automatically assigns the printing couple(s) to the designated newspaper page. An optional press-based version allows the relevant printing couple or subassembly to be selected directly. 

Production management 

The console level can be expanded with a production management system containing modules for master files, job scheduling, presetting and data storage. Various permutations of these modules feature in Commander press lines the world over. Under the banner KBA EasyTronic we also offer two optional modules for automating press start-up (Easy Start) and run-down (Easy Clean Up). Both help to cut waste. 

The Commander CT boasts an extensive module-based automation system which, with the exception of the waterless Cortina, no other newspaper press in the global marketplace can match. Alongside the standard features – DriveTronic dedicated cylinder drives, NipTronic pressure adjustment and performanceproven RollerTronic roller locks – it embraces a number of options ranging from FanoTronic fan-out compensation to Plate-Ident plate recognition and WebTronic self-regulating web tension control. 

Another Cortina attribute integrated in the Commander CT to enhance cost efficiency is our PlateTronic automatic plate-changing system, which can change individual plates, all 64 plates in a four-high tower (96 in a 6/2 press) or all 192 (288) plates in three towers in two minutes or less. Dedicated cylinder drives allow automatic blanket washing with CleanTronic while the plates are being changed. This saves time and dramatically increases output. As with the other automation components available for newspaper presses, the technology we offer is way ahead of the field and our practical experience is unparalleled in the industry. 

The compact press height of just 4.5m (14ft 9in) means that the distances between the individual printing couples in a four-high tower are almost as short as in a satellite press, reducing fan-out in 4/4 production by 50% compared to a conventional four-high tower. So accurate colour registration is possible even in conventional wet offset. For wider presses we offer optional fan-out compensation via FanoTronic, which is available in a choice of versions and automation levels. 

The inking units on the Commander CT each have a dedicated drive, three forme rollers, a new type of film roller and an optimised roller geometry. This reduces dot gain, enhances image quality on solids and image stability where ink take-up is low. The roller constellation with two direct ink trains responds swiftly to changes in inking commands and generates much less ink mist, as is demonstrated on a daily basis by the pilot installation at the Main-Post. Automatic ink pumping is available as an option. 

Since spot colours are rarely used in newspaper production the Commander CT features one-piece ink ducts. The duct roller and ink knife can be accessed by pivoting the knife holder. The rollers are cleaned by a wiper blade. An automatic washing system for the inking unit is available as an option, with a pivoting bridge roller enabling the dampening unit to be washed at the same time. For extended production runs we recommend installing a high-precision ink temperature control unit. RollerTronic resets the forme rollers automatically at impression ON. 

The ability to preset and pre-ink the inking units automatically reduces startup waste, which on the Commander CT is already lower than on conventional tower presses. An optional RIP interface is available for downloading digital pre-press data for presetting the inking and dampening units. 

Optimised spray dampeners 

The Commander CT incorporates specially modified triple-roller spray dampeners installed in the pre-moistening position. The fount solution is transferred to the chrome roller via a cylinder-wide spray bar with eight nozzles (twelve on the 6/2). Metering is regulated by controlling the impulses to each individual nozzle. The outer nozzles can be regulated separately to eliminate marginal toning. The fount solution is transferred contact-free, virtually eliminating the risk of contamination. Each press section has a dedicated water-preparation unit. As an option the water temperature and mixing data can be displayed at the console. 

Streamlining the paper flow from reel reception to the reelstand is a key factor in enhancing production efficiency. The Commander CT, like our other presses, can be embedded in a customised reel logistics system by configuring it with a high-performance KBA reelstand and our Patras paper-reel transport system (see separate brochure). 

KBA Patras reel-handling system 

Patras is module-based to support a wide range of versions from manual, semiautomatic or automatic reel loading to a complete reel logistics system, enabling it to be customised to suit individual production scenarios and architecture. At the highest level of automation the new reels are unloaded from the delivery trucks, stored, prepared for splicing and loaded onto the reelstands, and the used cores removed, with virtually no manual intervention. With Patras A, reel logistics from reception to stub disposal are embedded in a networked production flow, bringing substantial savings in time, labour and waste, and thus in costs. 

Depending on output, web width, reel diameter, maximum reel weight and other specifications, the Commander CT can be configured with one of two newgeneration versions of our Pastomat beltless reelstand, whose reliability is well proven. The Pastomat C (classic) is engineered for web speeds of up to 13mps (2,560fpm), a maximum web width of 1,680mm (66in), a maximum reel diameter of 1,270mm (50in) and a maximum reel weight of 1.8t (3,968lbs). For wider or faster newspaper presses we have developed the heavy-duty Pastomat CL (classic large), which can handle web speeds of up to 17.2mps (3,386fpm), a maximum web width of 2,520mm (991/4in), a maximum reel diameter of 1,524mm (60in) and a maximum reel weight of 6t (13,228lbs). 

Both models (see separate brochure) are driven and braked by robust AC servo motors via the reel core and have infinitely adjustable divided arms for simultaneously handling reels of different widths, enabling them to support pagination changes on the fly. They also have distributed operating screens and are fully embedded in the press control system. Our Pastomat reelstands function reliably and safely, even at high web speeds and when handling heavy reels, need little maintenance and are easy to operate. 

The superstructure on the Commander CT is as compact as the press itself, yet easily accessible. Presshall roof clearance permitting, the CT can, of course, be configured with the standard Commander superstructure whose performance has been well proven on countless press lines. But whichever you choose, our superstructures are engineered for productivity, diversity and high-speed edition changes, thanks to ergonomic turner bars, short web paths and a straightforward production flow for multiple web widths – not to mention our proven high-performance folders. 

Superstructure 

The ergonomically positioned slitters on the draw rollers enable the web to be slit into half-width ribbons or, as an option, into quarter- and half-width ribbons. The ribbons are monitored by photoelectric sensors as they are guided to the former infeed via easy-access turner bars. 

As with all Commanders, extras include bay-window rollers, insertion decks and double decks. The double deck (with the option of two pairs of turner bars instead of four) enables the web to be guided to the left or the right over the former without repositioning the turner bars, which cuts changeover times. Another option for relieving crew workload allows the turner bars to be positioned by remote control from the console. The page count for the individual signatures can be adjusted quickly and easily to changes in specifications. Colour and/or cut-off register controls can also be installed upon request. 

Folder superstructure 

The standard constellation is two adjacent formers, but presses can also be configured with formers positioned one above the other (eg four formers in a balloon arrangement). AC drives for the draw and transfer rollers enable web tension to be controlled with absolute precision. Our WebTronic web-tension measurement and control system, wellproven in major installations, is available as an option. Other extras include a length gluing unit, cross/length perforator, skip slitter and ribbon stitcher. 

There is a choice of four cutting-edge folders, each of them engineered for a specific output and page count. Our KF 3 folder has a maximum hourly output of 75,000 80-page broadsheet copies in straight production. Our heavy-duty KF 5 folder can handle up to 90,000 120-page copies per hour straight. Our new highend folder, the KF 7, is engineered for 90,000 144-page broadsheet copies per hour. The RF 3 gear folder can process copies with up to 160 broadsheet pages. 

All KBA folders are highly automated and fully embedded in the shaftless drive and press presetting systems. The diameter of the folding cylinder can be infinitely adjusted to copy thickness, either at the folder itself or from the console. 

Over- and underfold adjustment is also integrated in the presetting and control systems. Conversion between collect and straight mode is actuated by pushbutton at the folder or via the presetting controls at the console. If desired, the KF 5 folder can be fitted with a single or dual quarterfold capability and/or a section stitcher for delivering stitched magazines in either production mode. 

Both our compact models are available as floor-mounted versions with adjacent reelstands for standard industrial buildings with low roof clearance, but they can also be configured with underfloor reelstands. A unique feature of the waterless Cortina and conventional wet offset Commander CT is that they can be stacked to form eight-high towers, eg for press extensions or new installations in existing high press halls where there are restrictions on press length. They can therefore eliminate the need to relocate to greenfield sites by enabling capacity to be expanded at existing premises. And with energy prices heading skywards, substantial bottom-line benefits can be gained from limiting the size of the production hall and thus energy consumption for climate control. 

On top of this there are ergonomic benefits to be gained, since the press crew can access the individual printing Big 6/2 Commander CT press line for the New York Daily News, a prominent US newspaper couples via platform lifts on either side of the tower, so they no longer have to climb stairs. The reduced press height also means that the crew have a clearer overview of the entire installation. The compact design thus creates a more attractive workplace that enhances staff motivation and reduces physical strain, particularly for older workers whose numbers are sure to increase in many countries as a consequence of demographic changes. 

Conclusion: Our innovative compact press range, KBA Competence, embracing our keyless, waterless Cortina and conventional wet offset Commander CT, is a timely response to demands by newspaper publishers and the workplace expectations of future production staff.