perfecting

Offset Printing Technology Perfecting Technology

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Why sheet reversal in print production?

• Production time is virtually cut to half - second pass is not required - additional press capacity • No intermediate storage in the print shop for sheets printed on one side • No re-piling required • General reduction of wash-up times • The substrate‘s dimension does not change • Improved paper run properties

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Sheet travel innovations

Possible features for perfecting Transfer jackets

Perfecting device

Sheet travel guides and air bars Impression cylinder jackets © 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

A sheet guidance concept for perfecting presses

• Concept of single-revolution impression cylinder, each sheet is exposed to the same surface • Double-sized storage drum for format changes • Single-sized and rough-chromed reversing drum with pincer gripper system • Jacket technologies after the perfecting device on transfer drums and impression cylinders Sheet travel observing sensor

Venturi sheet guide plate © 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Double blower bars

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Print Media Academy

Sheet travel and ink transfer in perfecting mode

Impression cylinder with special ink repellent jacket after perfecting device

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Sheet transfer via cam controlled pincer gripper

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Print Media Academy

Sheet transport in straight printing with a 1-2-1-Drum Concept Pincer gripper system of the reversing drum

Press: Speedmaster SM 52

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Gripper guided sheet transport of a Three-Drum-System

• 4 transfer points with one perfecting device • Storage drum for format change • During perfecting, the pincer gripper ensures work-and-turn of the sheet - approx. 180° rotating movement Movement of the pincer grippers of the pincer grippers - Format deviations between +1/-2 mm in circumferential direction are tolerated

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Storage drum with rotary suckers

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Print Media Academy

The double-sized storage drum

• Double-sized drum with paper-stretching rotary suckers - Eccentric rotary suckers for circumferential and lateral adjustment of the sheet - They hold the sheet’s rear edge until the pincer grippers take the sheet • Format change in circumferential direction • Uniform and reliable sheet alignment during perfecting

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Some important aspects of perfecting

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

The eccentric perfecting drum with Pincer Gripper System

• Rough chromium plated, ink repellent surface • Pincer gripper compensates trimming tolerances + 1 mm, -2 mm • The work and turn process requires an additional gripper margin

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Perfecting technolgy with eccentric perfecting drum

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© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Reduced contact to freshly printed sheet – reduced wash-up times

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Print Media Academy

Jacket technology for transfer drums I and III

TransferJacket Plus

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

"TransferJacket Plus" for transfer drums I and III

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Jacket surface with ink repellent coating

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Reduction in wash-up times

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Enhanced range of materials in straight printing and perfecting

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Print Media Academy

Evolution of impression cylinder surfaces

SerialJacket

Refined Surface

Chromium plated, homogeneous surface structure • Ink splitting properties

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Chromium plated Irregular form, size and position of the spheres Ink-repellent properties Mainly used for perfecting presses Can be used with UV inks

PerfectJacket Extreme fine, irregularly distributed • Combined with ink repellent silicone layer •

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Print Media Academy

Highest print quality and productivity based on exchangable cylinder jackets with PerfectJacket Technology • Impression cylinder jacket with ink repellent surface - irregular and very hard intermediate layer sprayed onto the surface with extremely hard titanium compound as well as with an additional ink repellent surface made of silicone • Increased printing quality • Reduced cleaning • Higher ink coverage possible • PerfectJackets can be changed easily

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Extremely durable Titanium Compound

Silicon layer

Steel Carrier

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Print Media Academy

Further development impression cylinder jacket "PerfectJacket Plus" • Ink repellent perfecting impression cylinder jacket "PerfectJacket Plus" • 3 major components form this improved jacket: - Stainless steel base plate - Irregularly structured, intermediate layer of a Titanium compound - Ink repellent silicone sealing • Finer, reduced structure of sheet carrying contact spots

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Adjustable cylinder gap between the impression cylinder and the subsequent transfer drum With cardboard

With paper

Impression cylinder

0.1 mm up to 0.6 mm

Transfer drum I © 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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0.6 mm up to 0.8 mm

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Print Media Academy

Extension of the delivery by two transfer drums for perfecting presses • Same sheet transfer system just as between printing units • Entirely printed sheet is transferred gently to the delivery grippers without suction bar • Single-diameter transfer drum I with chrome jacket and • Double-diameter transfer drum II equipped with SuperBlue

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Print Media Academy

Economical aspects of the workflow

5 x 5 colours, 16 pages - 15,000 sheets Finishing

Hourly rate 100 % 2nd pass

Hourly rate 100% 80% of max.15,000 s.p.h. = 12,000 s.p.h.

Makeready time and printing Costs: 100% Makeready time: 69 min.

Total: 5 h 17 min.

Intermediate storage

1st pass Cleaning of the 1st printing unit Makeready and printing

Finishing

Hourly rate 154% 80% of max.12,000 s.p.h. = 9,600 s.p.h.

Costs: 75% Makeready time: 53 min.

Total: 2 h 46 min.

© 2004 Print Media Academy • Wolfgang Wallowy • Perfecting.ppt

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Cleaning of two printing units Makeready and printing

Offset Printing Technology Perfecting Technology

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