perfecting by ....

Offset Printing Technology Perfecting Technology

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

Sheet travel innovations

Possible features for perfecting Transfer jackets

Perfecting device

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

Double blower bars

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

Sheet travel and ink transfer in perfecting mode

Impression cylinder with special ink repellent jacket after perfecting device

Sheet transfer via cam controlled pincer gripper

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

Storage drum with rotary suckers

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

Some important aspects of perfecting

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

Perfecting technolgy with eccentric perfecting drum

•

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

Jacket technology for transfer drums I and III

TransferJacket Plus

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

"TransferJacket Plus" for transfer drums I and III

•

Jacket surface with ink repellent coating

•

Reduction in wash-up times

•

Enhanced range of materials in straight printing and perfecting

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Print Media Academy

Evolution of impression cylinder surfaces

SerialJacket

Refined Surface

Chromium plated, homogeneous surface structure • Ink splitting properties

•

• •

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 •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

Extremely durable Titanium Compound

Silicon layer

Steel Carrier

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

0.6 mm up to 0.8 mm

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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.

Cleaning of two printing units Makeready and printing

Offset Printing Technology Perfecting Technology