Rapida 106

Rapida 106
The World's Makeready Champion
©KBA
Content
The new 106 in detail
ƒ Configuration and targets
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©KBA
Operation concept and design
Control console and software concept
Feeder/Infeed
Substructure
Printing tower
Delivery
Coating tower
Summary
Configurations & Targets
The demands of our customers:
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Offer a wide range of services on the market to differentiate
from other companies
Highest demands in automation and productivity
Use all possibilities of inline-finishing as well as
inline-quality control
Garantee a high availability in terms of production
The standard for high
production capacities: Rapida 106
©KBA
The Rapida 106 in detail
©KBA
Tecnical Data
Max. paper format
740 x 1060 mm
Paper format (optional)
750 x 1060 mm***
Max. print format
730 x 1050 mm
Print format (optional)
740 x 1050 mm***
Max. production speed
18,000 Sh/h *
Max. production speed with perfecting
15,000 Sh/h *
Substrates
0.04 – 1.2 mm **
Substrates for perfecting
0.06 – 0.8 mm **
Pile height feeder / delivery
1300 / 1200 mm
Pile height feeder / delivery (Non-Stop)
1000 / 1100 mm
Plate format
795 x 1060 mm
* The referred given capacity is the capacity that is possible corresponding to the technical features of the machine. It is still dependent on local
conditions and the used materials.
** special equipment and options are not included in the basic price of the machine
*** not with perfecting or ASP
©KBA
Operating Concept and Design
©KBA
Operating Concept and Design
With revised details in design and colour the
Rapida 106 is now even more high-quality
©KBA
Operating Concept and Design
• Approved operating concept
• Functionally arranged operating
elements
• Optimized touch displays with short
cuts
• Coloured, intuitive menu-driven
operation
Benefits:
• Optimum accessibility with modern
design
• More user-friendly due to touch
displays with shortcuts
©KBA
Operating Concept and Design
Competitive Comparison
Rapida 106
XL105
• modern design
• modern design
• easy to operate via
Touch displays
• easy to operate
Roland 700
• machine concept 18
years old but with new
face (HiPrint)
• operation still the same
©KBA
Lithrone S 40
• modern design
• operating elements quite
confusing
Control Console and Software Concept
©KBA
Control Console and Software Concept
Control Console ErgoTronic Professional
• Complete machine control is
based on MS Windows
• A clear structure of console menus
for all sequences of production
• Job changeover program
• Maintenance display
©KBA
Control Console and Software Concept
Control Console ErgoTronic
Benefits:
• Reduction of makeready due to
upgraded software
• Open system structure which allows
the connection to the companies´
network
©KBA
Control Console and Software Concept
Competitive Comparison
Rapida 106
• Modern visualisation
XL105
Roland 700
Lithrone S 40
• Easy; direct operation
• Modern
visualisation
• Grafic elements 15 years • Needs time to get used
old
to
• Windows user-interface
• Easy, direkt operation
• Based on DOS
• Windows user-interface • New design probably at
drupa 2008
©KBA
• A lot of text
• Windows user-interface
Making the most of the format
©KBA
Making the most of the format
106cm
102cm
75cm
©KBA
72cm
+ 3 Nutzen = + 20%
105cm
Making the most of the format
Competitive Comparison
Rapida 106
XL105
Roland 700
Lithrone S 40
• Maximum paper format
740 x 1.060 mm
750 x 1.060 mm option
• Maximum paper format • Maximum paper format
750 x 1.050 mm
740 x 1.040 mm
780 x 1.040 mm option
• Maximum paper format
720 x 1.030 mm
• Maximum print format
730 x 1.050 mm
740 x 1.050 mm option
• Maximum print format
740 x 1.050 mm
• Maximum print format
710 x 1.020 mm
©KBA
• Maximum print format
715 x 1.020 mm
770 x 1.030 mm option
The DriveTronic Feeder
©KBA
The DriveTronic Feeder
• Shaftless drive of feeder head,
suction belt and pile
• Continuous upwards movement of
pile
• 1 suction belt and 3-chamber low
pressure system
• Ultrasonic double-sheet-control
• Capacitive double-sheet-control
and package control
• Reduction of waste sheets due to
„collecting sheets“ function
(forward / backward direction)
• Laser pointer for a perfect pile
alignment
©KBA
The DriveTronic Feeder
Optimizations of Feeder / Infeed
• Easier operation of feeder head
• Improved blowing air supply for
difficult substrates
• Improved guiding plates for a more
secure sheet run
• New predriving elements allow a
more secure positioning of the
sheet
„The new DriveTronic feeder can
compete absolutely with the XL. In
case of certain materials it is even
more reliable.“
Owner of a XL105
after a continuous test of the Rapida 106
©KBA
The DriveTronic Feeder
DriveTronic Sidelay SIS
• No adjustments to be made
• Reduction of makeready times
• Paper now has the double time for
alignment
• Little mechanical burden
In 2007 the SIS was
awarded the
GAFT Technolgy Award
©KBA
„The SIS is something really
convincing because it is very easy
to operate and works very
exactly.“
Owner of a XL105
after a continuous test of the Rapida 106
The DriveTronic Feeder
Benefits:
• Production without interruption due to a
reliable positioning of the sheets
• Reduction of makeready times due to
automatic format adjustment via console
• Easy to operate
• Little service costs
©KBA
The DriveTronic Feeder
Competitive comparison - Feeder
Rapida 106
XL105
• shaftless drive via servo
motors
• drive via Cardan-shaft
©KBA
Roland 700
• drive via Cardan-shaft
• pile transport in very
small steps
Lithrone S 40
• drive via Cardan-shaft
and chains
• lots of vibrations due to
this drive system
The DriveTronic Feeder
Competitive comparison – suction belt table/infeed
Rapida 106
• 1 suction belt
XL105
• 1 suction belt
• all air and format settings • all air and format
can be saved in the
settings can be saved
memory
in the memory
• DriveTronic Side Lay SIS • front lays are
adjustable individually
• front lays are adjustable
via a motor
individually via a motor
©KBA
Roland 700
Lithrone S 40
• 2 suction belts and
• front lays adjustable via a 2 protection belts
motor
• front lays manually
adjustable
• 2 suction belts
The Substructure
©KBA
The Substructure
Gripper System
• Structured gripper pads with
flexible plastic inlays
• Ceramic coated, wear resistant
gripper tips with a high friction
degree
• No adjustments at grippers
necessary in case of substrate
change
Benefits:
• Time is saved during substrate
change
• Low maintenance
©KBA
The Substructure
Sheet Guidance
Benefits:
• Sophisticated air control for an
optimum sheet transport
• All air settings can be memorized
©KBA
• Venturi-guiding plates
create air cushions so
the sheet can slide
without any contact along
the system to the next
impression cylinder
• Comb suckers in front of
impression cylinder are
smoothening the sheet
• Blowing pipes in front of
printing zone prevent
accidential contacts of
the sheet
The Substructure
Competitive Comparison
Rapida 106
• 0,06 – 1,2 mm
universal
• Little suspectibility to
failures
• Sheet guidance with air
cushions
©KBA
XL105
• Motoric up to 1 mm
• Sheet guidance with air
cushions
Roland 700
• Manually (about 2
min/PU setting time)
• Motoric with
QuickChange Job
Lithrone S 40
• Manually (about 5
min/PU setting time)
The Perfecting Unit
©KBA
The Perfecting Unit
Sheet guidance
Benefits:
• Best perfecting register
• Wide variety of substrates
• No doubling
©KBA
• Blowing pipes on top of the
storage drum are
smoothening the sheet
• Air cushions to avoid
smearing of the freshly
printed sheet
• Blowing pipes in front of
the printing zone make
sure that there is no
contact of the sheet and
the drums
• Turning suckers tighten
the back edge of the sheet
for a precise sheet transfer
The Perfecting Unit
Sheet Guidance
• Monitoring systems below
perfecting and in delivery via
cameras
• Additional cameras in following
printing units possible
Benefits:
• Comfortable supervision of the
sheet guidance
• Fast corrections of air settings via
console
©KBA
The Perfecting Unit
Operating Concept
Benefits:
• Makeready saving, fully automatic
change between straight printing
and perfecting mode
• Easy handling due to user-friendly
depictions of all air settings
©KBA
The Substructure
Competitive Comparison - Perfecting
Rapida 106
XL105
Roland 700
Lithrone S 40
1:2:1
2:2:1
2
2:2:2
15,000 Sh./ h
15,000 Sh./ h
12,000 Sh./ h
15,000 Sh./ h
0.06 – 0.8 mm
0.03 – 0.6 mm
0.04 – 0.4 mm
0.07 – 0.45 mm
Print Format
Print Format
Print Format
Print Format
max. 720 x 1050 mm
max. 730 x 1050 mm
max. 730 x 1050 mm
max. 720 x 1030 mm
min. 400 x 480 mm
min. 410 x 480 mm
min. 340 x 480 mm
min. 360 x 520 mm
©KBA
The Printing Tower
©KBA
The Printing Tower
ColorTronic Ink Duct
• Bending-resistant, ceramic coated
ink duct roller
• Wear free ink metering due to
35 ink blades with hard metal tips
• Constantly the same positioning of
ink duct roller to ink duct due to
protection rings
Benefits:
• Reproducibility of ink settings
• Very low maintenance
©KBA
The Printing Tower
ColorTronic Ink Duct
„What is convincing, is the
improved reproducibility of the
inking unit settings.“
Owner of a XL105
after a continuous test of the Rapida 106
• Bending-resistant, ceramic coated
ink duct roller
• Wear free ink metering due to
35 ink blades with hard metal tips
• Constantly the same positioning of
ink duct roller to ink duct due to
protection rings
Benefits:
• Reproducibility of ink settings
• Very low maintenance
©KBA
The Printing Tower
Inking Unit
• Fast reaction due to one stream
inking unit
• Primary ink train to backside forme
rollers via roller bridge
• Ink stream separation during
„impression off“ – ink distribution on
the rollers stays homogeneous
• Low roller speed avoids ink fog and
sputtering
Benefits:
• Very little start-up waste due to the
fact, that the ink-water balance can
be reached very fast
• Savings in costs, as no spezial inks
are needed for high speeds
©KBA
The Printing Tower
Disengage Inking Unit
Savings in time:
Cleaning time before
recommissioning
6 x disengage / week
10 min
= 60 min
• Separation of the complete roller
section from the drive
• No use of roller paste needed
• No cleaning before the
recommissioning necessary
Savings in costs:
Hourly rate of machine
50 weeks x 1 h x 300 €
300 €
15.000 €
Benefits:
• Saving in time = saving in money
• Rollers of inking unit will last longer
©KBA
The Printing Tower
Disengage Inking Unit
„Attention – Damage of rollers
due to dry run! Put a bit of print
oil or paste on the disconnected
rollers. This protects the roller
from wear and damage.“
• Separation of the complete roller
section from the drive
• No use of roller paste needed
• No cleaning before the
recommissioning necessary
Operating manual XL105
Benefits:
• Saving in time = saving in money
• Rollers of inking unit will last longer
©KBA
The Printing Tower
Dampening Unit
• Switching on / off via console
• Overdampening via console
and delivery
• Oscillating rider roller (option)
reduces ghosting effects when
printing special colours
• Hickey picker, optional it is
possible to activate the
differential drive during
production
©KBA
The Printing Tower
Competitive Comparison – Ink Duct
Rapida 106
XL105
• Zero position of ink
• Use of a foil -> no
duct is long-term stable reproducibility
• Low maintenance
because it is a closed
system
• Highly reproducible
• Exchange of foil
at least once a week
Roland 700
• Ink-duct zero is adjusted • Ink-duct zero has to be
manually (takes about
set manually once a
5 min/PU, has to be done month (takes about 1h
twice in 3 month,
for a 6-colour-machine)
the older the machine is, • Ink zone springs are
the more often it has to
worn after 3 years
be done)
• Ink wipers are guided
linear
©KBA
Lithrone S 40
The Printing Tower
Competitive Comparison – Inking Unit Concept
Rapida 106
• Very fast reacting
• Continuous duct roller
speed
• Process stable
©KBA
XL105
• Duct roller speed
regulated in steps ->
reacts more slowly
• Special ink for highest
speed necessary
Roland 700
• Fast reacting
• Continuous duct roller
speed
Lithrone S 40
• Copper oscillators lead
to dirty inks
• „good enough“ is the
quality standard
The Printing Tower – Plate Changing Systems
©KBA
The Printing Tower
Fully Automatic Plate Change
• Simultaneous plate change in
3 cycles
• Straight printing machine: 3 min
Perfecting machine: 6 min
• In case of semi automatic plate
change about 1,5 min/PU
Benefits:
• Savings in time of 3 - 15 min
(4 - 12 PU) with FAPC compared
to SAPC
• During the plate change the
operator is free for other tasks
©KBA
The Printing Tower
DriveTronic SPC
• Simultaneous plate change in all
PU´s also in case of a perfecting
machine
• Parallel makeready procedures
• Variable beginning of the print
©KBA
The Printing Tower
DriveTronic SPC
Benefits:
• Savings in makeready time due to parallel plate change and washing
procedures
©KBA
The Printing Tower
DriveTronic SPC – Profitability Consideration
Mio.
sheets
Basic data:
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Rapida 106-8 SW4
1 operator, 1 helper
250 days, 3 Shifts, 7.4h / shift
Max. printing speed 15,000 Sh./h
Ø runlength 10,000 Sh.
ƒ Makeready / job
with SPC
without SPC
Increase of
annual
production by
42
41
40
39
6.3 mio.
sheets
38
37
36
35
16 min.
28 min.
34
33
ƒ Revenue = Production costs + general
costs + 10% earnings
32
(social conditions and working time due to german guidelines)
31
30
with SPC
©KBA
without
SPC
The Printing Tower
DriveTronic SPC – Amortization Comparison
If no cost advantages are given to the final customer, you will have a amortization
time of
34 months
for the complete machine
with SPC (not giving cost advantages to the final customer)
without SPC
month
0
2
©KBA
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
45
The Printing Tower
Plate Ident
• Cameras identify the printing
plates with a special Data-MatrixCode
• Job data are loaded automatically
by the LogoTronic Proffesional
• The register is preadjusted
through the measurement of the
register marks
Benefits:
• With this, there is no problem of
mixing up plates during a job change
• Reduction of waste due to
preadjustment of the register
©KBA
The Printing Tower
Competitive Comparison – Plate Change
Rapida 106
• SAPC 1,5 min/PU
• FAPC simultaneous
change in 3 cycles in
all units= 3 min
• Parallel makeready
due to DriveTronic
SPC
©KBA
SM/CD 102
Roland 700
• SAPC Autoplate
takes about 2 min/PU
• SAPC 1 min/PU, one
after the other
• FAPC Autoplate
Advanced 45 sec/PU
• FAPC 1 min/PU, one
after the other
• Parallel makeready due
to DirectDrive
Lithrone S 40
• 2,5 min for 6 PU
The Printing Tower – Washing Devices
©KBA
The Printing Tower
Washing Devices
Roller washing
Blanket washing
Impression cylinder washing
• Preselection of individual washing
programs for each inking unit at
the console
• Predefined washing programs
Benefits:
• Quick and simple one-man
operation
• Used washing cloth is
eliminated via domestic waste
©KBA
The Printing Tower
Clean Printing of Blanket- and Plate Cylinder
• Up to 20 sheets pre-selectible
• At a speed of v = 15,000 Sh./h
t= 5 sec
• Normal washing programs last
about 3-5 min
Benefits:
• Savings in time with washing
program about 1 min
• Production stability also for very
thin substrates
©KBA
The Printing Tower
WashTronic for UV-intermediate Dryers
example: 12,000 Sh/h
2 wash runs
savings in time: 12 min
4000 sh= 20 min
without
WashTronic
4000 sh = 20 min
4000 Bg = 20 min
2 minutes lamp start
2 min. waiting time due to danger of explosion
3 minutes washing
2 minutes lamp cooling
4000 Bg = 20 min
with WashTronic
4000 Bg = 20 min
4000 Bg = 20 min
Benefits:
• 15% more productivity
• Less operating costs due to high durability of UV dryers
©KBA
The Printing Tower
Competitive comparison – washing devices
Rapida 106
XL105
• 1 washing bar for
blanket and
impression cilinder
washing
• 2 washing bars for
parallel blanket washing
and impression cylinder
washing
• Efficient usage of
washing cloth
• Small storage boxes –
have to be refilled very
often
©KBA
Roland 700
• Brush washing system
needs about 3h
maintenance / month
• Washing solution needs
to be disposed as
hazardous waste
Lithrone S 40
• 2 washing bars
• No parallel washing
The Delivery
©KBA
The Delivery
• Complete air regulation is
controlled and memorized via
console
• Optimized air settings for sheet
transport and positioning of
sheets in delivery
• Format positioning of suction
rings automatically (option)
©KBA
The Delivery
Non-Stop-Systeme
• Lowering rollo goes in
automatically in sheet running
direction
• No need to reduce speed
• Approved manual non-stopoperation at the feeder
• Complex Non-Stop-logistic systems
by Krifft & Zipsner
Benefits:
• Highly efficient printing for
mas circulations
• Uninterrupted production
©KBA
The Delivery
Non-Stop-Logistik
„The decision for our investment was
in the end only between the XL105
and the Rapida 106. Finally the
KBA-machine convinced us with its
complete Non-Stop- and Logistics
system.“
Former MAN customer
©KBA
The Delivery
VariDry Dryer-Technology
• UV-dryers interchangeable
between delivery and printing units
• Patented handling for a quick
change
Benefits:
• High flexibility of machine
configuration
• Short makeready times within
production
©KBA
The Delivery
Competitive Comparison – Non-Stop-Systems
Rapida 106
XL105
• Lowering rollo which
• Rack is manually put
goes automatically
against sheet running
inside and outside in
direction
sheet running direction • Speed needs to be
• Uninterrupted
decreased
production
©KBA
Roland 700
• Laterally retracting plate
system, dependent on
material
• Speed needs to be
decreased
Lithrone S 40
• Expensive double
delivery
The Delivery
Competitive Comparison – Non-Stop-Systems
Rapida 106
XL105
• Lowering rollo which
• Rack is manually put
goes automatically
against sheet running
inside and outside in
direction
sheet running direction • Speed needs to be
• Uninterrupted
decreased
production
Roland 700
• Laterally retracting plate
system, dependent on
material
• Speed needs to be
decreased
Attention – damages of delivery! The manual
upwards and downwards movement of
auxiliary pile and main pile is not controlled one
to the other.“
„Attention – damages of non-stop-rack!
Deformed rack bars may have an influence on
the non-stop operation.“
Operating manual XL105
©KBA
Lithrone S 40
• Expensive double
delivery
The Coating Tower
©KBA
The Coating Tower
• Chamber blade system by
Harris & Bruno
3
4
©KBA
• Anilox rollers in light construction
• All functions controlled via
console (with H&B system)
• Extended delivery 1x, 2x or 3x
The Coating Tower
Supplying System
• Fully automatic varnish supply
and cleaning system for
dispersion and UV-varnishes
• Short makeready due to
automatic cleaning of all varnish
bearing components within very
short time (some minutes) –
without manual cleaning after the
automatic process
Benefits:
• Varnish change about 1–2 min
(disp. ' disp.; UV ' UV)
• Varnish change from one type to
another about 10 min
(dispersion ' UV)
©KBA
Additional Equipment
Competitive comparison – Coating tower
Rapida 106
XL105
Roland 700
• Chamber blade system • Chamber blade system by • Chamber blade system
Harris & Bruno with
Tresu
by Tresu
console operation
• Bad cleaning result
• Harris & Bruno optional
• Tresu optional
• Varnish change with
• Very good cleaning
QuickChange Coating
system
at least 15 min.
©KBA
Lithrone S 40
• Chamber blade system
Harris & Bruno
Additional Equipment
Comparison – change of coating plates / anilox rollers
Rapida 106
• CP: automatically,
t = 2 min
XL105
• CP: manually, t = 8 min
• AR: manually with
• AR: manually, rollers in Multiloader-System
light construction,
t = 3 min
t = 2-3 min
©KBA
Roland 700
Lithrone S 40
• CP: automatically with
• CP: manually, t = 10 min
opt. QuickChange Clamp 2 persons needed
t = 5 min
• AR: manually, rollers in
• AR: manually with rollers light construction
in light construction
t = 3 min
t = 3 min
Rapida 106 – Conclusion
• The Rapida 106 offers the widest range of possibilities for saving time in
makeready.
• It is highly automized to reach best production results.
• The wide range of substrates and the huge spread of individual configuration
options allow the use of our machine in each business model.
• KBA offers the best remote maintenance and a wide range of services
©KBA
Overview of the main differences
Stabilisation – Makeready time reduction – Inline-quality control
Characteristics
Rapida 105 (P40)
Rapida 106
Paper format
740 x 1.050 mm
740 x 1.060 mm
Print format
730 x 1.050 mm
730 x 1.050 mm
740 x 1.050 mm
Sheet guidance feeder /
infeed
Handling feeder /
delivery
Modules to reduce
makeready time
Quality control features
©KBA
Good sheet guidance
also for
thicker substartes
Optimized sheet guidance
also for very thin substrates
User friendly for
Experienced operators
Very user-friendly,
easy adjustability
DensiTronic SIS
DriveTRonic SPC, SIS, Plate
Ident, Parallel Processes
QualiTronic, offline colour
measurements
QualiTronic Professional,
Inlinecolour measurement,
Sheet Marking, DensiTronicPDF
Notes for the sale
ƒ
ƒ
©KBA
Composition of new functional packages (UV,
hybrid etc.)
Preferred vendors for following units
ƒ Cooling unit BALDWIN
ƒ Washing equipment BALDWIN
ƒ Coating unit HARRIS & BRUNO
ƒ Dryers KBA VARIDRY / GRAFIX
Thank you very much for your attention
Koenig & Bauer AG, Werk Radebeul bei Dresden
Friedrich-List-Str. 47
01445 Radebeul
www.kba-print.com
©KBA