Today's print arena demands entrepreneurship

51 Pages·2013·4.14 MB·English

43
SEPTEMBER |2013
PRODUCTS|PRACTICES|PERSPECTIVES
Contents
KBA
Editorial 2
Sheetfed Offset
Printers experience
large Rapida 164 3
WSQF: Rapida 145 boosts
folding box production 6
Interview:
KBA ColdFoil Infigo SF110 8
High-quality label printing in France 11
Rapida 145-8-SW4
at Himmer in Augsburg 12
High tech in northern Bavaria 14
Amcor: 35m of cutting-edge
printing technology 16
UV inert drying with the
AirTronic Drum 18
Smurfit Kappa Interbox:
new job for old Rapida 20
France: two premieres at Martinenq 21
USA: two new Rapida 145s 23
Winston Packaging:
Rapida for 100th birthday 24
Complete Solutions:
KBA workflow in Asia 25
Even in these challenging times KBA continues to focus on innovation. One example of this is the new large-format Rapida 164 unveiled at the
KBA expands portfolio for
KBA plant in Radebeul in June packaging printers 26
Web Offset
The willingness to explore new avenues is paramount
France: Lenglet grows with KBA 28
Today’s print arena demands
Newspaper
BDU: big goals with small formats 30
entrepreneurship Badisches Tagblatt opts for
Commander CT 32
Commander CL for Ouest-France 33
Cortina with coater for Trier 34
T KBA retrofits offset with inkjet 36
he print industry is currently At the end of the day all of this is tion and bold entrepreneurship.
undergoing a fundamental trans- not possible without innovation and Successful internet printers are
Digital
formation. In addition to shifts in investment in terms of processes not the only example of this. Other
customer and consumer priorities and technology, as well as the will- examples from various business Printing with the RotaJET:
and changes to common produc- ingness of managers and employees areas and regions can be found in new chances for newspapers? 38
tion processes, the internet, tablet to explore new avenues. Some firms this issue of KBA Report along with Special applications
PCs, smartphones and digital tech- react too late or are overwhelmed the latest information regarding
KBA-MetalPrint:
nologies are all changing print’s role with the growing pressure from new technologies and processes.
three premieres in China 40
in the media arena. Demands for changes, competition and costs. Perhaps you’ll find some inspiration
Genius 52UV in St. Petersburg 41
faster, easier, cheaper, more target- Takeovers and insolvency sadly often for your business and together we
KBA-Metronic:
group orientated and cross-media go hand-in-hand with this fast shift. can push print forward.
easy batch identification 42
print products are just some of the
Marking with the alphaJET evo 43
challenges facing service provid- However, phases of change also Klaus Schmidt
Shorts 44
ers and their suppliers every day. offer opportunities for creative ac- [email protected]
Editorial
Exciting times for print
ClausBolza-Schünemann
president and CEO, Koenig & Bauer AG
News from print over the last few device, the Kindle, he could turn viable investments are being con- The second acquisition targets the
months has been gripping. Super- into a lucrative business package. tinually postponed, which doesn’t relatively small, but valued market
regional headlines were made in make our planning and capacity for the direct decorating of glass
particular when Axel Springer Ver- Both events are examples of the utilisation any easier. But there is containers and other high-quality
lag sold its newspaper titles the enormous shift in the print and no point complaining about this. hollow bodies made of plastic and
Hamburger Abendblatt and Berliner media landscape. They paralyse For years we have adjusted our or- metal. Kammann Maschinenbau in
Morgenpost, which have belonged and make some in our industry ganisation with our own resources Bad Oeynhausen, Germany, which
to the media house since its found- insecure when making corporate accordingly to a changing and, in is now majority-owned by the
ing, as well as magazines to the and investment decisions. These some segments, smaller market. KBA Group, is the global market
Funke MedienGruppe (formerly strategies, which seem divergent We regularly develop new products leader in screen printing presses
WAZ). Additionally, the Washington at first sight, also demonstrate that and processes to meet the chang- for directly decorating glass. Such
Post was bought by the founder of following the motto “print is dead, ing demands of our manifold cus- glass packaging is mainly used for
Amazon and eCommerce guru Jeff long live online” alone is not the tomers, and invest in print markets cosmetics, perfume and spirituous
Bezos. The strange thing about only best way forward. There are which we have not previously ad- beverages in the top price class. It
these stories is that while Springer too many unfulfilled expectations dressed. Today the simultaneous is a growing market even in thresh-
sold prominent print titles to boost in the online sector. But it is a fact shrinking and growing in different old countries, such as China and
its eCommerce activities by pur- that print and online will grow to- market segments no longer present Brazil, where prosperity is rising.
chasing further portals, Jeff Bezos gether into multi-channelled com- a contradiction as long as compa-
used his fortune earned with online munication solutions with which nies have the resources to master The times for print, and everyone
trading to buy a newspaper popular money can be made. The same is this balancing act. who is involved in this industry,
in Washington and far beyond. true of analogue and digital tech- remain exciting. This dynamic shift
nologies in the printing process As part of our diversification strate- presents us with great challenges,
All parties involved seem to see an itself. Both processes have their gy, over the past months our atten- but it also opens up new opportu-
opportunity from the deals, other- strengths and limitations, and are tion was directed to the varied and nities. In these times of change,
wise they wouldn’t have followed increasingly used in combination continually growing packaging mar- I hope that both you and us will
through. Mathias Döpfner from as part of modern marketing strate- ket. We have been well positioned make the right decisions and will
Axel Springer has often alluded gies. in this market for a long time with be successful in the end.
to his strategy “move away from our Rapidas for folding carton board
print and to online” and thus ac- In terms of new orders KBA also printing. However, up to now we Yours,
cepts that with it one of the largest feels the effects of latent uncer- have not been active in the further
German media houses is gradually tainty with regards to future de- expanding market for flexible pack- Claus Bolza-Schünemann
turning into a digital trading plat- velopments in parts of the print- aging which is dominated by flexo
form for cars, property and other ing industry. Economic weakness and gravure presses. This is set to
consumer goods. Jeff Bezos is giv- in some key sales markets has change with the majority takeover
ing little away in terms of his goals strengthened this trend. This is of Italian press manufacturer Flexo-
and strategies. However, we can particularly the case for media- tecnica. Along with acquiring new
assume that he is fond of the influ- related and ad-dependent print customers, we aim to address exist-
ential brand the Washington Post, sectors, such as commercial, book, ing packaging customers, who are
which in combination with the magazine and newspaper printing. active in several sectors, with our
strongly propagated digital reading Even technically and economically new products.
2 Report 43 | 2013
Sheetfed Offset | New Products
On the hottest day of the year head of sheetfed
marketing Jürgen Veil remained cool when
presenting the new Rapida 164
dedicated drives at the plate
cylinders that support simultane-
ous plate changes in all printing
units in only 100 seconds. KBA
Plate-Ident carries out on-press
plate recognition, pre-registration
and checks that the plates are
correctly positioned. Further make-
ready processes, such as washing
with CleanTronic Synchro, are also
possible in parallel.
Coating formes can even be
changed automatically while the
press is printing, as can changing
Peak performance now also in format 7B (65in) anilox roller sleeves. The high-flow
doctor-blade chamber with a re-
300 large-format printers duced filling volume is also a new
feature. The increased speed at
which the ink flows supports faster
production speeds and optimised
experienced the new Rapida 164
sheet brakes ensure an outstand-
ing pile formation for commercial
and packaging printers. Further
new features include the AirTronic
At Drupa 2012 KBA unveiled the new Rapida 145 which defined new benchmarks in large format. On 20 and 21 June 2013 delivery, energy-saving VariDryBLUE
as temperatures soared some 300 current and potential KBA large-format users from over 20 predominantly European drying systems and the new Ergo-
countries seized the opportunity to take a closer look at the new Rapida 164 as part of an open house event at the plant Tronic console with integrated
in Radebeul. The new Rapida 164, available since the beginning of this year, supersedes the vastly successful Rapida 162 measuring systems.
in format 7B.
A
plinth-mounted six-colour ver-
sion of the Rapida 164 with
coater and extended delivery was
the focus of a series of live dem-
onstrations. It redefines perfor-
mance parameters in the 120.5
x 164cm (47.4 x 64.57in) format
class. Jürgen Veil, head of sheetfed
marketing, introduced the automa-
tion components and presented
the print demonstrations. Thanks
to dedicated drive technology and
a high level of automation, time
consuming manual adjustments
are no longer required at the Drive-
Tronic feeder. The press runs at a
maximum output of 15,000sph
simply by pressing two buttons.
Like the Rapida 145, the Rapida
164 is equipped with DriveTronic
SIS sidelay-free infeed. Along with
automatic plate changing, there is Ralf Sammeck KBA's executive vice-president for the sheetfed product house was very satisfied with attendance at the two-day open house event.
also the option of DriveTronic SPC He welcomed a total of more than 300 experts from nearly 20 countries to the KBA plant in Radebeul
Report 43 | 2013 3
Sheetfed Offset | New Products
After presenting the Rapida 164, Jürgen Veil then turned up the heat with live demonstrations The presentations and print demos were avidly watched by the visiting print professionals
of a six-colour Rapida 145 and a ten-unit Rapida 106 for commercial printing
Simultaneous printing off the demonstrations with the and less distance between lamps in terms of migration and odour if
and makeready Flying JobChange between the first and substrate. Further benefits in- the consumables are tailored to the
The visitors then saw an everyday and sixth printing unit. clude a reduction in diffused light, conditions in the inert chamber. A
job change. The printing plates UV radiation and the build-up of short time ago in sheetfed offset it
were mounted with DriveTronic Speciality from Radebeul: heat. The efficiency of UV lamps is was not possible to create a stable
SPC and after the first proof densi- UV inert drying in sheetfed offset continuously monitored by a sensor. nitrogen barrier. Reasons for this
ty measurements and colour regis- Along with the live press demon- Lamps can be exchanged in just a were the gripper system, the open
ter were checked. In less than four strations, Jürgen Veil introduced few seconds by hand. KBA also of- cylinder gap and the large distance
minutes the Rapida 164 produced the new KBA VariDry UV dryer. fers UV inert dryers for Rapidas as between the printing cylinder and
a typical packaging job. Blue and It is particularly energy efficient an option. These offer enhanced inert chamber, plus rigid substrates
silver were used in the fifth and thanks to cutting-edge reflectors crosslinking as well as fewer risks coming into contact with the inert
sixth printing units as special inks.
The following job change was really
something special. Printing units
one and two plus the coater were
uncoupled during plate changing
and blanket washing. The ink ducts
were washed and the coating was
pumped out likewise in parallel. In
less than three minutes the first
proof of the next job could be seen.
Following register and density
measurements, within five minutes
a four-colour packaging job had
started. While the press carried
on printing at full speed, coating
continued to be pumped out and
anilox roller sleeves were changed
in preparation for the next job.
After the press was stopped, plate
changes, blanket washing, coating
forme changes and filling the doc-
tor-blade chamber with new coat-
ing all took place simultaneously
in under two minutes. Then the
coater and printing units one and
two were reconnected and after
about six minutes the Rapida 164
was printing the next job. A world During press demonstrations Hendrik Gasch could barely keep up with mounting the plate-loading cartridges with plates for the next job,
first in large format then rounded- given the frequent and fast job change ensured by DriveTronic SPC
4 Report 43 | 2013
Sheetfed Offset | New Products
Dirk Winkler (left on the gallery) presented
high-quality cold-foil finishing with the KBA
ColdFoiler on a Rapida 106 equipped with two
coaters
Using figures from his company Wilfried
Grieger (r), managing director of technology
at Walter Grieger Offsetdruck from Nettetal,
explained the Rapida 164’s significantly enhan-
ced productivity compared to the Rapida 162.
At the end of the event he signed a contract
for a second Rapida 164 with Ralf Sammeck,
KBA executive vice-president for the sheetfed
product house
chamber. KBA has solved this prob- large format. Highlights included:
lem with its new AirTronic Drum printing cosmetic packaging on
suction cylinder. A 19-unit Rapida a brand-new Rapida 76 equipped
106 with inert equipment at Amcor with DriveTronic SIS and Drive-
Tobacco Packaging in Rickenbach, Tronic SPC, 4/4-colour high-speed
Switzerland ensures an outstanding commercial production including
print and finishing quality, it also fast job changing on a ten-colour
eliminates the need for additional Rapida 106, producing commer-
process steps (see pages 18-19). cial jobs on a six-colour Rapida
145 with coater at speeds of up to
Using figures Wilfried Grieger, 17,000sph, printing at 20,000sph
managing director of technology at with inline colour control accord-
Walter Grieger Offsetdruck from ing to grey balance with Instru-
Nettetal, explained the press’ sig- mentFlight from System Brunner
nificantly enhanced productivity on a five-colour Rapida 106 and last
compared to the Rapida 162. The but not least producing intricately
first press from the new Rapida finished packaging on a double-
164 series has been in operation coater Rapida 106 with inline cold
here since summer 2012. In the foil finishing (KBA ColdFoiler). For
meantime the press on display at the first time KBA showcased four-
the open house is now in operation over-four production on an eight-
at his firm enhancing efficiency still colour Rapida 105 with HR UV The guests enjoyed an evening storm, there was enough time for
further. dryers. In a few short hours the in- steam boat river cruise on the guests to exchange thoughts on
ternational sheetfed offset experts Elbe with views of the baroque old the day and light-hearted discus-
Highlights in all format classes gained an insight into the high town as the boat cruised through sions.
Along with the official premiere of standard of printing and finishing the Elbe locks to Pillnitz and back.
the Rapida 164, participants were technology inside KBA Rapidas in Between listening to Dixieland
treated to presentations on six other all format classes. music, the occasional stop to pick Martin Dänhardt
sheetfed presses from half-size to up late guests and a short thunder [email protected]
Report 43 | 2013 5
Sheetfed Offset | Packaging
Rapida 145 speeds up folding box production
Job change times cut by a third at WS Quack + Fischer
WS Quack+Fischer in Viersen, near the Dutch border, belongs to a raft of medium-sized packaging printing firms in
Germany who print on the cutting-edge Rapida 145 from KBA. The deal for the plinth-mounted six-colour version
integrated in an automated pile logistics system was sealed at Drupa 2012 where the press was launched. The traditional
packaging firm fired up the press at the beginning of the year.
The six-colour Rapida 145 with
coater is equipped with the usual
extras for packaging production
including options to cut makeready
times. Simultaneous plate chang-
ing is often not necessary for
typical high run lengths between
30,000 and 100,000 sheets. Au-
tomatic plate changing is enough.
It is also not vital for the coater to
have parallel anilox roller and coat-
ing forme changes, it is more im-
portant to have a second washing
bar. Two washing bars cut the time
needed to either wash blanket and
impression cylinders simultane-
ously or just the blanket cylinders
by 50 per cent. Extensive preset
functions and DriveTronic SIS side-
lay-free infeed, which compared to
The Rapida 145 is WS Quack + Fischer’s main press. Right to left: managing director Heinz Eicker, managing director Hermann-Josef Schmitz and sales conventional sidelays is more toler-
and marketing director Thomas Eicker at the delivery ant with regards to the flatness of
substrates, cut makeready times by
a third compared to previous press-
es. Reliable inline quality control,
“We don’t talk much about the Folding box production: such as QualiTronic ColorControl,
things which are in fine working or- faster and more elaborate is essential for packaging printers.
der,” says Hermann-Josef Schmitz Since its installation the Rapida The press has enhanced the high
managing director of the firm 145 handles the majority of com- level of quality valued by the cus-
which was founded in 1897. This pany’s print jobs. Together with
is true of the Rapida 145. There another large-format press it
wasn’t anything to talk about. The prints 300,000 to 350,000 sheets
press had to be installed quickly every day. This equals 550 to 600
before the new year as the peak million folding boxes a year, 200
production time for companies million more than ten years ago.
producing packaging for the retail What is more, today most fold-
sector is the first six months of a ing boxes are far more difficult
year. This project included more to produce. The diversity of dif-
than just press delivery and inau- ferent folding boxes is increasing
guration. New foundations had to due to new products and fashions,
be laid, a complete logistic system plus the trend towards special col-
was planned precisely, the roof ours is growing. Gold and silver
had to be first lifted off and then are used to increase a product’s
replaced, and the existing 17 year perceived value and coatings are
old Varimat 142 had to be disman- applied to enhance the packag-
tled. All of the planning and pro- ing’s visual qualities. In addition,
ject steps worked out perfectly, production cycles have shortened
just as the new press arrived the significantly. This is coincides with
old one went. The team from WS the company’s philosophy which
Quack+Fischer and KBA did a bril- is based on a high level flexibility. The firm also regularly invests in die-cutting technology ensuring short manufacturing times
liant job. during all production stages
6 Report 43 | 2013
Sheetfed Offset | Packaging
The Rapida 145 boosts capacity with its higher output, significantly shorter makeready times and
extensive quality controls
Three modern folding gluers ensure that the products are processed fast. They are equipped with
various additional extras to add the finishing touches the end products
was packaging two cups on top of tion from printed folding boxes.
each other. This saves material, The latest research findings are
requires less space in the refrig- adopted by WS Quack + Fischer,
erator and eating the snack in the especially those solutions which
car is also very easy as it can be make the manufacturing process
stored easily in a car’s cup holder. more environmentally friendly.
The plinth-mounted Rapida is integrated in an automated logistics system The packaging was originally de- When doing this the firm also
signed with the company Peter places great importance on keep-
Kölln/Elmshorn for McDonald’s ing the complete process chain in
tomer still further. Hermann-Josef a huge step forward in terms of in Poland who were looking for mind. What is the point of print-
Schmitz: “The Rapida 145 has it all quality levels with this new press. a car-friendly packaging solution ing without alcohol if the cutting
when it comes to makeready times, Quality and creativity are impor- for portions of cereal and yogurt. dies need to be cleaned with dis-
automation, quality control and lo- tant to the firm which is why it Today even Lufthansa is one of putable solvents? Why be FSC or
gistics.” was awarded with a Carton Award the main users of this packaging PEFC certified when the firm’s
in the “All other food” category solution. “This award was a huge energy supply is generated by fos-
Winner of the Carton Award 2012 by Pro Carton und ECMA last honour for us as we won against sil fuels? WS Quack + Fischer has
WS Quack + Fischer has taken year. The award-winning solution other prominent and established all the conventional certificates
manufacturers,” says managing associated with manufacturing
director Heinz Eicker. The com- primary and secondary packaging
pany’s small but efficient team for food. A biomass heating system
Company history of developers were behind such is fed with base board suppliers’
spectacular packaging and also non-reusable pallets which alone
1897 Foundation of printing house Quack + Fischer other new innovations which have cuts CO² emissions by 200 tonnes
in Viersen, Germany. Longstanding subsidiary of the attracted not quite as much atten- a year. Alcohol-free printing and
Kaiser-Tengelmann Group tion. There is often little room to the use of low migration inks and
1980 Foundation of packaging producers WS be creative as the press operator’s consumables are standard. Regular
in Wassenberg, Germany guidelines have to be followed so checks are carried out to make
1999 Merger of both companies to form WS Quack + Fischer, that the packaging printing pro- sure hygiene standards are in ac-
Move to location in Viersen cess can take place automatically. cordance with BRC/IoP.
2002 Expansion of production capacity to 420m folding boxes a year
2005 Upgrade of prepress activities Ecology as an entire process WS Quack + Fischer are ideally
2007/ Expansion and modernisation of cutting department Food packaging in particular has to equipped to meet future market
2009 be produced in an environmental- demands with regular investment
2011 New technology for engineering department and prepress ly friendly way. Many carton and in new kit, such as the Rapida 145.
2012 Modernisation of press room with the installation of the ink manufacturers, and research
Rapida 145 and development institutions fo- Martin Dänhardt
cus on reducing or avoiding migra- [email protected]
Report 43 | 2013 7
Sheetfed Offset | Interview
Dirk Winkler, head of the print technology
department at KBA in Radebeul
Right: Folding box for a whisky bottle using
silver cold foil
KBA ColdFoil Infigo SF110: High-tech solution for cold foil transfer
Spectacular inline effects –
KBA Report: Why should users
invest in inline finishing with cold
foil?
Prolific and economical
Dirk Winkler: Nowadays, it is rare
for a Rapida press to leave the KBA
Inline finishing by way of cold foil transfer has been around for at least 15 years – unfortunately, however, it is often rather factory without a coating unit. It is
wasteful in its handling of the expensive foil, or simply far too slow compared to the otherwise attainable press output. thus only natural to consider add-
With the ColdFoil Infigo SF110 module, by contrast, KBA offers a solution which is far superior to many other systems in ing cold foil to the range of inline
terms of quality, productivity and cost-efficiency. KBA Report* spoke to Dirk Winkler, head of the print technology depart- capabilities. Cold foil offers spec-
ment at the Radebeul facility. tacular, eye-catching effects which
would be very expensive to achieve
in an offline process, e.g. hot foil
KBA Report: Dirk, could you ex- stamping, assuming they could be
plain briefly the process behind the realised at all. And compared to
KBA ColdFoil Infigo SF110 system? metallic pigments in inks and coat-
ings, cold foil stands out with unri-
Dirk Winkler: The ColdFoil In- valled brilliance, rub resistance and
figo SF110 is a joint development overprintability.
of KBA and our Dutch partner
Vinfoil. The system uses two off- KBA Report: Which are the most
set printing units to implement an appropriate fields of application for
essentially conventional cold foil such an investment?
transfer process: An adhesive sim-
ilar to an overprint varnish is ap- Dirk Winkler: First and foremost,
plied in the style of a register-true packaging and label applications.
spot finish through the ink duct of But there is also considerable po-
the first printing unit. In the sec- tential for high-quality commercial
ond unit, the foil web is brought Above: Photorealistic print through products, security printing and
into contact with the substrate overprinting of a gold-foil screen element facsimile editions. As it is possible
in the nip between the blanket to create not only solid areas, but
and impression cylinder, and the Left: Cosmetics packaging with gold effect also positive and negative types,
aluminium coating on the metal- achieved with a yellow screen printed over lines, logos, screen image elements
lised carrier film is transferred to silver cold foil and gradations in astoundingly fine
the substrate in the areas where resolutions, packaging and graphic
adhesive was applied. The sheet designers can now realise sophis-
can then be overprinted with con- ticated design ideas which were
ventional or UV inks in the subse- seemingly impossible in the past.
quent units. Where high-quality Screen cold foil elements with
cold foil effects are to be achieved shaded overprinting, in particular,
on non-absorbent surfaces such lend the results unbelievable real-
as plastic films, UV adhesives and ism – photorealistic print is raised
inks are required. to a whole new dimension.
8 Report 43 | 2013
Sheetfed Offset | Interview
Above: Cold foil reels with silver and gold
KBA Report: In the Radebeul aluminium coatings, on the left also with a
training centre, the ColdFoil In- diffraction pattern
figo SF110 system is installed on a
Rapida 106. Is it planned to make Above left: Configuration example with the
the system available for other for- ColdFoil Infigo SF110 system assigned to the
mat classes? first and second units of a seven-colour Rapida
106
Dirk Winkler: We have already
fitted cold-foiling modules to large- Left: The ColdFoil Infigo SF110 system in action
format presses, though not yet the on a Rapida 106 in the KBA training centre
highly automated KBA ColdFoil during the open house in June 2013
Infigo SF110 system. But if large
format printers show genuine in-
terest, we are certainly open to the mend a coating unit to protect the On practically all installations for Dirk Winkler: The necessary de-
idea. overprinted cold foil in the deliv- foil overprinting, the foil web is sign and planning expense would
ery pile and during downstream fed into the unit from the operator only be sensible to cater for very
KBA Report: Does KBA recom- further processing. That is also side of the press. One exception is frequent changes between over-
mend a particular press configura- the rule for most of our custom- the Rapida 106-6+L which was in- printed foil, foiling over print and
tion for the use of cold foil? ers, for example on the Rapida stalled at Heynen in Kleve in 2008. UV casting. If customer interest
106 at Model Obaly in Opava in On this press, the foil reel stands arises, it is technically feasible, and
Dirk Winkler: The customer is the Czech Republic. On the 19- behind the delivery and the web the KBA cold foil module is predes-
free to decide. For maximum flex- unit Rapida 106 at Amcor Tobacco is fed above the delivery and along tined for such a solution.
ibility, however, we recommend Packaging (see article on page 16 the length of the press to the cor-
that a press should have at least in this issue), the module is locat- responding printing units. Irrespective of the above, it is a
six printing units, i.e. foil trans- ed at the fourth and fifth units, as relatively quick and simple process
fer in the first and second units the first three units are used for KBA Report: Is it also planned to to switch the assigned units to use
and then at least four colours for the application and drying of ad- permit flexible positioning of the inks in the normal manner if cold
the overprinting. We also recom- hesive and effect primers. module on the operator side? foil is not required for the coming
L T T L 6 5 4
3 2 1 C
Configuration of the Rapida 106 in the KBA training centre (right to left): Corona tower (for printing and cold-foil finishing of plastics);
units 1+2 cold foil; units 3-6 process colours; double coating with intermediate drying (for further effects on top of the cold foil); final drying
Report 43 | 2013 9
Sheetfed Offset | Interview
i
jobs. You just have to remove the re- standard silver cold foil is about
Website:
maining adhesive from the first duct € 0.20 /m². Gold, bronze and oth- www.vinfoil.com
and wash down the rollers, cut the er colours are also available. And
foil web before/after the unit and fix there are furthermore many dif-
the end on the unit frame to permit ferent effect foils with 3D, diffrac-
fast re-threading later, and mount a tion and hologram patterns for use
different blanket. as non-screen elements. Silver is it must not be forgotten that cold
what is used for most jobs, howev- foil is always less expensive than
KBA Report: How much does the er, and gold effects are thus often metallised card or composite sub-
metallised transfer foil cost today, produced with yellow-dominant strates.
and which metallic colours and ef- overprinting on a silver foil. Some
fects are available? customers nevertheless insist on KBA Report: What distinguishes
an actual gold foil, as the diverse the KBA ColdFoil Infigo SF110 sys-
Dirk Winkler: KBA cooperates overprinting options then provide tem from competitor solutions?
with all certified foil manufactur- for particularly authentic gold
ers who supply high-quality stand- shades in the image. But when- Dirk Winkler: Three points are
ardised foils. The market price for ever we are talking about costs, decisive for economical cold foil
transfer:
(cid:116)(cid:1)(cid:1)(cid:71)(cid:66)(cid:84)(cid:85)(cid:1)(cid:78)(cid:66)(cid:76)(cid:70)(cid:83)(cid:70)(cid:66)(cid:69)(cid:90)(cid:1)(cid:85)(cid:73)(cid:83)(cid:80)(cid:86)(cid:72)(cid:73)(cid:1)(cid:66)(cid:86)(cid:85)(cid:80)(cid:14)
mated and parallel pro-
cesses, e.g. reel changing and Reel unwinding and splicing is accommodated
reel preparation; in the readily accessible side section of the
(cid:116)(cid:1)(cid:1)(cid:84)(cid:85)(cid:66)(cid:67)(cid:77)(cid:70)(cid:1)(cid:81)(cid:83)(cid:80)(cid:69)(cid:86)(cid:68)(cid:85)(cid:74)(cid:80)(cid:79)(cid:1)(cid:88)(cid:74)(cid:85)(cid:73)(cid:1)(cid:73)(cid:74)(cid:72)(cid:73) ColdFoil Infigo SF110 module
speeds and reliable product
quality;
(cid:116)(cid:1)(cid:1)(cid:78)(cid:74)(cid:79)(cid:74)(cid:78)(cid:74)(cid:84)(cid:70)(cid:69)(cid:1)(cid:71)(cid:80)(cid:74)(cid:77)(cid:1)(cid:68)(cid:80)(cid:79)(cid:84)(cid:86)(cid:78)(cid:81)(cid:85)(cid:74)(cid:80)(cid:79)
through options for web split-
ting and multiple refeeding of
the partially used foil.
If only smaller patches of foil are re-
Unlike less automated solutions, quired over the format width, web
such as the FoilStar from Heidel- splitting avoids wasting the unused
berg or the Komori Cold Foil Sys- areas of the web. Up to six separate
tem, the reels are not mounted ribbons with a minimum width of
above the printing units, but in- 15cm each can be guided to the
stead fed in conveniently from relevant transfer zones. In case of
a separate loading station. That only intermittent transfer in the
means that reels can be changed circumferential direction, the op-
while production is running, and tion MFU (MultiFoilUse) enables a
World record candidate! The combination of ColdFoil Infigo SF110 and Rapida 106 allows cold foil only a very short interruption is foil web to be returned to the nip
transfer at production speeds up to 15,000sph necessary to allow automatic web several times with a correspond-
splicing. The makeready time for ing offset on each pass. The user is
the KBA cold foil system is thus able to reduce foil consumption by
significantly shorter, and much less up to 88 per cent.
manual intervention is required.
KBA Report: Has KBA also re-
With this KBA solution, everything leased the so-called UV casting
is optimised to ensure constant process?
web tension and smooth, continu-
ous foil transport at high produc- Dirk Winkler: UV casting is a
tion speeds. That is naturally also process in which the structure of
very beneficial in respect of quality. a holographic or diffraction pattern
Specifically: Instead of dancer roll- is copied onto the still wet surface
ers, which could damage the metal- of a UV coating from a film web.
lised layer and contaminate the There is no actual material trans-
press with abrasion dust, we use fer and similarly no adhesive to be
dedicated drives to control the web applied. Instead, the cold foil unit
tension. And as the rewinding of must be positioned in the area of
the waste foil could introduce dis- the UV coater. KBA also offers this
turbing unbalances, the waste here solution upon customer request.
runs into a funnel shredder, and is
Web splitting – here with three ribbons aligned to the individual images – is one of the material- subsequently compacted into a dis- * Interview by Dieter Kleeberg
saving options for the KBA ColdFoil Infigo SF110 system posal container. [email protected]
10 Report 43 | 2013