The New Dimension in Large Format: Large-format sheetfed offset more efficient than ever

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Koenig & Bauer have spent the last few weeks showcasing its Rapida 145 (max. sheet format 1,060?×?1,450?mm) and Rapida 164 (max. sheet format 1,205?×?1,640?mm), a new generation of large-format sheetfed offset presses. The new press generation caters to packaging, commercial and web-to-print companies producing with a high output, the shortest possible makeready times, and a very high degree of process integration.

Rapida 145 and Rapida 164 set benchmarks in performance

For this purpose, the new generation of large-format sheetfed offset presses is equipped with all sorts of technical details and automation features needed to cater to both the current and the future requirements of these companies. For instance, with:

• Production speeds of up to 18,000?sheets/h (Rapida 145) or 17,000?sheets/h (Rapida 164) for extremely short production times (with High-Speed package)?
• Extensive automation of all processes for the shortest possible makeready times and maximum output
• Full integration into the print shop workflow for the shortest possible throughput times from order placement through to product delivery

The ultimate goal of implementing this new, highly automated technology is to make printing companies even more successful and to keep them one step ahead of the competition.?

Process reliability & uninterrupted print production

Today’s printing companies often consider themselves to be logistics experts. This is why substrate logistics play a key role in the new jumbo press generation from Koenig & Bauer. Fully automated systems enable uninterrupted production processes. They form the backbone for high process reliability combined with maximum production output, and integrate the following features:

• Tried-and-tested logistics components that have been perfectly tailored to the requirements of printing companies
• High-performance, automatic nonstop systems at the feeder and delivery, including ones that are also specifically for processing thick cardboards
• Close integration of press control, nonstop systems and pallet transport for high production reliability

DriveTronic dedicated drive components are key automation modules at the feeder and delivery and in addition to lending the presses from the Rapida 145 and Rapida 164 series their unmistakable appearance, they also ensure no adjustments are needed, infeed processes proceed reliably, and sheets are aligned exactly – even when working with highly sensitive substrates. Together with the DriveTronic SIS with its sidelay-free infeed, a unique selling point of the Koenig & Bauer sheetfed offset presses

• the time available for aligning sheets increases – even when printing at maximum capacity
• even sensitive substrates can be processed reliably and free of markings
• the sheet alignment process requires no presetting.

In addition, everything is integrated into the automatic format adjustment.

Simultaneous processes for the shortest possible makeready times

Fast, simultaneous plate changes have become an established feature of Rapida sheetfed offset presses around the globe over the last few years. More than 2,200 printing units have already been equipped with DriveTronic SPC for simultaneous plate changes. Just like all the other DriveTronic components, the system is based on dedicated drives and is characterised by its high degree of reliability and efficiency. All printing plates can be changed within 51?seconds. Additional time savings result from the fact that other makeready processes take place in parallel with the plate change.

Rapida presses that are equipped with DriveTronic SPC also feature the Plate Ident function. It offers absolute process reliability, as data matrix codes on each printing plate ensure that the right printing plate goes into the right printing unit. Automatic loading of the presetting data into the makeready time memory in the printing press makes a further contribution to process reliability.?

Coating plates are also changed automatically – using DriveTronic SFC. The dedicated drive technology means that this can also be performed at the same time as other makeready processes. The ErgoTronic console is used to couple and decouple the coating forme cylinder. The actual change only takes around two and a half minutes. The coating plate can even be changed while production is running – as long as the coater is not required, or only the second coater is in use when printing on double-coater presses. When coating forme changes are particularly frequent, makeready times can thereby be reduced considerably.

The AniSleeve system makes changing the anilox roller sleeves in the coater more convenient and straightforward. A crane, or a second staff member, is no longer required to change the anilox rollers. The advantages of AniSleeve are:

• Safe and easy handling
• Considerable time savings when changing anilox rollers (a change takes around 2?minutes)
• Anilox roller changes can be carried out at the same time as other makeready processes

Automation down to the very last detail

The Rapida 145 and Rapida 164 large-format series are equipped with AirTronic deliveries. The double pile delivery represents the highest level of automation. It allows good sheets and waste to be separated into different piles to ensure only good sheets are forwarded to postpress. Both systems can be integrated into logistics systems. The automatic non-stop roller in the delivery provides the basis for uninterrupted print production and perfect pile logistics.

The control centre and main workplace for the operator is the ErgoTronic console. It can be configured to suit the operator’s needs. A large wall screen – larger than the printed sheet – shows an analysis of measurements made by the quality control systems in the press, while also ensuring that the operators can easily keep an eye on all running processes.?

ErgoTronic AutoRun offers the most innovative form of process automation – an intelligent job change system for industrial commercial printing involving standardised jobs and frequent job changes. However, even when the normal job change program is used on the ErgoTronic console, the makeready times can be shortened by up to 50?per?cent.?

All performance and efficiency packages for the new Rapida jumbo presses can be combined in a way that the respective printing operation requires, and that delivers the greatest possible benefits depending on the job spectrum, workflow, and configuration.

Learn more?

Visit koenig-bauer.com/newdimension for more exciting information about the new Rapida large format generation. Also, don't miss the recordings of the webinar series Technology Deep Dive - The New Dimension in Large Format .