KBA C16

Our modular Patras reel transport and logistics system is robust yet flexible, requires a minimum of maintenance and is compatible with all customary reelloading systems. Configurations range from manually assisted to fully automated, with retrofit automation and upgrades possible at any time. 

Our proven Pastomat C automatic reelstand with integrated infeed unit is engineered for reel weights up to 3 tonnes (3.3 US tons) and a maximum reel diameter of 1270mm (50in). Clearly laid out data screens at the reelstand and subsequent units to the folder aid the press crew by furnishing data on the current operating status. The Pastomat CL is available as an option for reel diameters up to 1524mm (60in). 

Engineered for a maximum web speed of 13mps (2,560fpm), the Pastoline accepts reels weighing up to 1.6t (1.76 US tons) and with a maximum diameter of 1270mm (50in). Controls are the same as for the Pastomat C and CL. 

The infeed unit integrated in both types of reelstand is extremely compact and maintenance-friendly yet has all the components necessary for precise web alignment. 

When it comes to ease of operation and cost efficiency, KBA reelstands are way ahead of the field. On top of this, their unique regenerative braking system with energy feedback reduces running costs. 

A superb print quality, fast changeover times, ergonomic operation, good stability, low maintenance and optimum flexibility: the printing units for the C16 were designed to deliver on every point. Their robust construction, practical automation level (plate change, roller bearings etc.) and ingenious details (settings for paper thickness) make the C16 the perfect tool for round-the-clock production of short, medium and long print runs alike. 

The C16’s film inking unit and dampening unit can handle even the most problematic and challenging images, delivering a high quality in every type of production and at any speed. Four forme rollers, some oscillating, ensure that the ink/water balance is achieved in a minimum of time during start-up. Large-diameter rollers guarantee uniformity and rich solids throughout the production run. They also reduce ink spray and mist. This is where the C16 scores over its rivals. And it is ideal for environmentally responsible alcohol-free printing. 

Each printing couple has its own dedicated AC drive (i.e. two per unit) for the fast, precise setting of the circumferential register with a minimum of mechanical input. Electric motors control setting mechanisms with much greater precision than mechanical systems. 

Dispensing with bearer rings eliminates needless wear and tear and also allows the nip between the blanket cylinders to be set to the relevant stock thickness with absolute precision. The gap between the side frames is much smaller, which improves stability and vibration resistance, and there is less load on the journals. Finally, the absence of bearer rings and the forces they generate reduces energy consumption and prolongs the service life of all the drive components. 

Our C16 features operator-friendly semi-automatic plate changing as a standard, while both the 55,000 and 65,000cph versions can be configured with optional automatic plate changers that are the fastest on the market. They can change the plates in a single couple or the entire press line in less than sixty seconds. With KBA automatic plate changers, jobs of fewer than 10,000 copies – which were previously the preserve of sheetfed – can now be printed cost-effectively on a web press. 

When actuated by push-button from the console panel, RollerTronic automatically sets and adjusts all the inking rollers in less than two minutes. Irksome time- and cost-intensive manual roller setting, and the hours of down time associated with it, are history. Rollers set with optimum precision ensure that ink is transferred uniformly across the entire width. RollerTronic dramatically reduces roller abrasion and thus the frequency with which rubber coatings must be replaced, thereby delivering further cost savings. It obviates uneven wear and tear arising from the incorrect positioning of the rollers relative to each other. Correct roller settings reduce maintenance costs and energy consumption while promoting optimum production conditions. 

The superstructure on the C16 is configured for straight-on production, but can be fitted with optional turner bars. All the web guide elements are easily accessible, even the former and slitter. A modular design and dedicated drives throughout allow the superstructure to be customised for specific production scenarios. 

The microporous turner bars are one of the many proven features that are unique to KBA. They no longer need to be set for different ribbon widths, and operate reliably with a minimal air cushion and superior ribbon guides. 

A next-generation slitter with motorised lower knife slits and trims cleanly with very little paper dust. Cutting and perforating modules can be included in the original build or added at a later date. 

A high level of press performance and production flexibility, rapid conversion and precision folding, yet low maintenance, total reliability and ergonomic operation are the properties demanded of today’s commercial folders. 

The P3 pin folder’s compact design and ease of access reflect its advanced technology. 

Our new P3 folder can produce over 30 different folds in a range of formats. Not only this, it is easy to operate via a swivelling touch screen directly at the folder delivery. 

We offer the benefit of a remotely adjustable first and second cross fold, and a quarterfold unit comprising a single module. This supports a wide choice of folds while dramatically shortening conversion times. The strike length and depth of circumferential and lateral perforation can be adjusted on the fly so as to adapt perforation and folding accuracy to stock type and production conditions with a minimum of waste. 

For outputs up to 65,000cph the P3 folder requires just one quarterfold. This is because the belt paths are short and broad, ensuring smooth copy transport. Intelligent, patented copy control in the quarterfold makes for a trouble-free folding sequence. It is user-friendly and requires no manual intervention. Production conditions are therefore always consistent irrespective of operator skill. Copies are slowed effectively and with a minimum of abrasion, and aligned in the direction of fold during deceleration. Our new, automatic copy control system is self-adjusting and exceptionally reliable regardless of production speed and copy thickness. As a result folding is consistently accurate, even during changes in press speed. The pneumatic belt system maintains a constant tension yet effectively prevents stretching. This reduces abrasion and thus maintenance input. Belt tension can also be adjusted on the fly. 

Among printers today the concept of an integrated workflow from order reception to print production and distribution is steadily gaining currency. The diversity of equipment and software installed means that shrink-wrapped packages are rarely appropriate, so workflows must be customised using existing kit with the addition of bought-in components where necessary. We offer suitable tools in the form of LogoTronic and LogoTronic Professional, and also work closely with prominent providers of proprietary software. This enables us to offer integrated networks based on JDF (Job Definition Format). 

A standard feature of all KBA commercial presses, the basic version of LogoTronic enables essential presetting data to be transferred directly to the press. It includes a CIPLink module for the CIP3-/CIP4- compliant transfer of data for press preset, with reel- and ink-data capture available as an option. The workflow is networked using the in-house hardware (server). Inkkey, colour and dampening data can be transferred to the press for presetting. 

As an option the console can be configured with LogoTronic Professional, an openarchitecture production management system that supports production monitoring, the digital flow of job and presetting data, and the systematic evaluation of production data. It connects the press to upstream production planning and scheduling systems and commercial IT. This wellproven system translates production and administrative data into meaningful statistics and makes for greater transparency by capturing press and operational data. 

LogoTronic Professional is a key link in the communication chain between the KBA press and the printshop’s management information system. New KBA presses can be embedded at any time in an existing LogoTronic Professional scenario with KBA sheetfed, newspaper and commercial web presses, delivering synergy gains and creating a uniform platform for all the presses in the printing plant. The database can be accessed either direct or, as an option, via JDF.