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H-UV Expert Session

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Komori H-UV

An Eco-friendly application taking process to new levels of efficiency

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1. The origins of H-UV.

2. Why we developed H-UV.

3. What is H-UV?

Komori H-UV

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The origins of H-UV

• Seven years ago we were evaluating curing systems.

• Benefits but many negatives.

• Maintain the benefits and get rid of the negatives.

• Develop with partners a new way of drying and new type of inks.

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The Origins of H-UV

• Many hours in development and testing.

• Ensuring the recipe worked time after time.

• The Return on investment ROI had a solid platform.

• Why? Many false applications in the past

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WHY WE DEVELOPED H-UV

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Why we developed H-UV.

• A constant drive for process efficiency.

• Constant battle to maintain competitive edge.

• Manufacturing requires innovation to progress.

• Komori has a 30 year history of innovation.

Process Technology

People

Press room efficiency

…Each leg is important independently but each is

reliant on the strong support from the other two legs’

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Why we developed H-UV.

Compete with digital

High cost of materials.

Printing on difficult substrates.

Print On demand requirements.

A constant battle to maintain a status quo!

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WHAT IS H-UV

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What is H-UV

Development of a unique lamp with unique wavelength.

Ink with specially developed photo initiators.

Combination of tested and certified products.

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What is H-UV ?

• H-UV is a combination of NEW Technology and utilizing tested and selected products

• Developed by KOMORI and only available from KOMORI

• H-UV is Unique!

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Conventional offset printing.

• The ink emulsion dilutes into substrate.

• Difficult to print on absorbent substrates.

• Requires a combination of methods to speed up manufacturing.

• Spray powder.

• Water based varnish, IR/Hot air.

• Standing time.

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The Future!

• Speed up the manufacturing process.

• Reduce production cost.

• Broaden your market possibilities.

• Improve margins.

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H-UV printing.

• The ink dries on the surface.

• Very little absorbency • Higher gloss levels

especially on low grade papers.

• No ‘dry back’ therefore uses less ink.

• Allows immediate finishing.

• Allows immediate reverse printing.

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H-UV printing

Reduced initial cost

Low Heat generation

Ozone free production

Environmentally friendly

Carton board printing possible

Plastic printing possiblel

Black Magenta Yellow

One H-UV lamp

Cyan

‘A system which can cure ink quickly using just one ozone-free UV lamp’

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H-UV benefits

A real alternative to conventional printing.

An application that increases your product quality, productivity and truly benefits your business.

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H-UV ink

Advantages for conventional and UV printers

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hubergroup H-UV inks

Advantages for conventional and UV printers

Printology H-UV Reto Andres

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Resins Oils Dry ink film

Resins Oils

Penetration

Evaporation

Conventional drying

Drying mechanism

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Problems with oilbased conventional inks

1 – uncoated offset papers

=> very slow drying, low piles

=> depending of water-/oil absorption of substrates

2 – non-absorbent substrates

=> very slow drying, low piles

=> Usage of spray powder

3 – coated offset papers => more and more rub, carbonating issues => varnishing necessary => Usage of spray powder

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Advantages UV offset

• Fast curing

• Inline finishing

• High chemical, mechanical resistances

• Highest gloss levels (OPV)

• Non absorbing substrates

• No spray powder

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UV

dry ink film oligomers monomers

photoinitiator

UV curing

Drying mechanism

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Electromagnetic spectrum

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Spectrum mercury UV – H-UV lamp

Wave length [nm]

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

200 260 320 380 440

Inks and varnishes must be adjusted to the lamp spectrum !

Heat

formation Ozone

formation

Surface curing UV varnishes

Depth curing Adhesion

Pigmented inks

Depth curing Adhesion

Opaque white

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Is H-UV able to improve conventional and UV offset printing?

- Drying - Carbonating - Need of varnishing - Other benefits ? - Areas of usage ?

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Drying / Curing differences

Standard UV ink H-UV ink

No spray powder needed !

No dependency on different substrates (water/oil absorption)

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conventional Non UV ink

Standard UV ink

Carbonating differences coated paper

H-UV ink

=> Lowest carbonating with H-UV => No varnish needed !

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oilbased

Print quality on uncoated offset paper

H-UV

=> More contrast => Brighter colours => Bigger gammut

=> Less ink consumption

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Possible applications / Benefits of H-UV inks

Packaging Commercial

On uncoated substrates: • More contrast • Brighter colours • Bigger gammut • Less ink consumption (up to 30%)

General: • Better drying/curing • No need of spray powder • No varnishing needed • Less temperature impact (plastics) • Inline effects / finishing • Less energy consumption

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NewV set KHS (high sensitive)

Uncoated, Coated papers / boards

Available ink series for H-UV

NewV poly KHS (high sensitive)

Metallised papers/boards, Plastic films

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Consumables Conventional HUV

Ink EUR/kg 8.00 15.00

Dispersion varnish EUR/kg 1.50 -

Varnish H-UV EUR/kg - 16.00

Spray powder EUR/kg 7.00 -

Energy cost EUR/kWh 0.14 0.14

Replacement HUV bulb EUR/piece 600.00

Consumables consumption Conventional HUV

Ink kg/year 1'800.00 1'620.00

Dispersion varnish kg/year 5'500.00 -

Varnish H-UV kg/year - 0.00

Spray powder kg/year 360.00 -

Energy kW/h 58.00 20.00

Energy consumption per year 189'312.00 65'280.00

Lifetime H-UV bulb - 750.00

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Working times Conventional HUV

Daily working time (2 shift) in h 13.60 13.60

Working days per year 240.00 240.00

=> h per year 3'264.00 3'264.00

Cost per working hour 290.00 290.00

Annual cost calculation Conventional HUV

Inks 14'400.00 24'300.00

Dispersion varnish 8'250.00 -

Varnish H-UV - 0.00

Spray powder 2'520.00 -

Energy 26'503.68 10'053.12

Replacement H-UV bulbs - 2'611.20

Total costs 51'673.68 36'964.32

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H-UV drying

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H-UV Drying

• Printing & Drying

– Drying technology

• H-UV Technology

– Power Consumption

– Efficiency

– Going Green

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PRINTING & DRYING

Sheetfed dryers - options

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Best technology available (Application vs. technology)

conventional

Sealer / Coating

Ink only

UV Offset

High Gloss Coating

Special Substrates

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Drying principles / options

79kW 1 day >90kW

No Dryer IR & HA Dryer UV Dryer EOP + 1

Absorption Evaporation Curing Slow process Accelerated drying Kick-started chain reaction

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Where does H-UV fit?

H-UV

conventional

Sealer / Coating

Ink only

UV Offset

High Gloss Coating

Special Substrates

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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DRYER - TECHNOLOGY

Let‘s have a look behind it

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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IR/HA Power Consumption

What for: IR lamps boosting temperature of paper and water

Effect: evaporation of water born materials

Costs: 52kW

What for: Hot Air for boosting ambient temperature in press

Effect: Creating environment to absorb water vapour

Costs: 18kW

What for: Exhaust enabling Air exchange

Effect: Removing hot, damp air to keep process going

Costs: 9kW

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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UV Power Consumption

What for: UV lamp creating radiation

Effect: broad exposure of radiation to the sheet

Costs: 71kW

What for: Exhaust to atmosphere

Effect: Removing ozone contaminated air to atmosphere

Costs: 7kW

What for: Water Cooling

Effect: Cooling of dryer parts in press to protect from overheating

Costs: 12kW

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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H-UV TECHNOLOGY

Let‘s step back and explain in detail

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Radiation

H-UV

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H-UV Dryer

H-UV lamp head

– Ozone free lamp

– Higher efficiency

– Less heat

– Built in Active Power Control (APC™)

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Efficiency

less energy, MORE Curepower

Matching of Components

H-UV Lamp

Electrical Control

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Sounds magical…

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H-U Lamps (K-Supply )

• UV lamp manufacturing

• Design

• Manufacturing

In house with equipment manufacturing unit

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Magic? – Science!

STANDARD

QUARTZ

QUARTZ

used for H-UV bulbs

Special metal halide „doping“

Original H-UV represents most advance technology

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H-UV bulb

Special lamp with tuned output: => Reducing Energy requirement by 66%

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H-UV Power Consumption

What for: Lamp creating H-UV radiation

Effect: High intensity H-UV output Costs: 16kW

What for: Lamp control

Effect: Keeping H-UV bulb and output stable Costs: 3kW

What for: Water Cooling

Effect: Cooling of lamp head and heat sink Costs: 4kW

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Lithrone GL40 – H-UV

One lamp H-UV dryer in the delivery

GL 40 H-UV

Line Current 42 A/~

Power (actual) 27 kW

Power (apparent) 29 kVA

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Printing technology

Focus Conventional UV Offset H-UV

Ink Only Very good Fair Very good

Protection Fair Good Good

High Gloss Poor Very good Very good

Special substrates Poor Very good Very good

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Gloss Technology Gloss Points

Oilbased print Varnish approx. 60

Waterbased Coating approx. 70

Primer + UV approx. 80

UV inks & coating (inline) approx. 90

H-UV inks & coating (inline)

up to 95

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Green Printing

Going green without worries • IPA free Print • Min. power consumption • Preserving the touch of paper • Safe for immediate post press handling

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Thank you for your attention! Uli Sause – Baldwin Technology

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Printology H-UV

Tony Carter

An Eco-friendly application taking process to new levels of efficiency.

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H-UV Sheet-fed sales 68 sheet-fed presses

2

8

2

4

4

7

2 2 1

2

3

2

1

1

2

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Market segments

Packaging Market

Added Value Market

On demand Printing

• H-UV is adaptable and flexible.

• H-UV proving that it can benefit all types of print markets.

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On demand market

Efficient production requirements.

High quality control, standards.

H-UV reduces material cost and increases available production time.

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Added value market

• Special substrates

– Creative papers, Cardboards, plastics ….

• High quality image

• Very heavy ink coverage

• High quality varnish

• Creative Drip off

• Ambitious creative prints

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Packaging market

• Huge reduction of energy consumption.

• Easier image match with other prints processes.

• Higher flexibility.

• Easier treatment of heat sensitive substrates.

• Higher Quality of Images.

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WHAT ARE THE REAL BENEFITS TO YOU.

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Improvements in productivity

Immediate back side printing (shorter total turnaround time)

Immediate drying, ready for finishing.

Prints on heat sensitive stocks

Reduction of ‘work in progress’ space.

Smaller press footprint. Heavy ink coverage

benefits.

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Overhaul Quality improvement!

• No changes in gloss or colour after drying.

• Quality of heavy images. • Quality of the printed dot • Reduction of marking

risks • Improved quality due to

powderless operation • Print on difficult paper

(difficult to dry) : Muncken, Chromolux…

• You can feel the paper!

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Benefits to the environment!

• Reduction of paper waste

• No powder pollution

• No ozone emission (waste of energy)

• No heat emission (waste of energy)

• Reduced compared to UV or IR drying electrical consumption

• Valuable factory space

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Production comparison

Komori LS 840P conventional

vs

Komori GL 840 H-UV

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CUSTOMER PROFILE

Commercial Printer

Equipment:

LS 529 HC H-UV (2012) 2,2

shifts/ week on yearly base.

GL 540 HC H-UV (2012) 2,5 shifts/ week on yearly base.

LS 840 P conv. (2009) 3 shifts/ week on yearly base.

K-STATION

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K-STATION DATA

Real data from real production.

Press Good copies /year

Plate changes/year

LS529 plus coater H-UV

19,350.000 4,830 plate changes

GL540 plus coater H-UV

24,100,000 5,520

LS840P Conventional

27,000,000 3,450

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Production details

• LS840P Conventional printing.

Description Data

Only APC year 3,540

251 Hours 4 mins 15 secs

Make Ready/ Year 3,540

2,006 Hours 34 mins

Waste sheets/Year M/R, colour, register

973,500 sheets 275 sheets

Production/Year 27,000,000 sheets

2,307 Hours 11,700c/hour

Faults due to set off 125,000 sheets 125,000 shts

Maintenance/Year 655 hours

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Customer request!

• H-UV Technology

• More productive

• Better quality

• Less maintenance

• Less paper consumption

• Less fault percentage

• Diversification

• Added value

• Figures…………..

Which configuration?

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GL 840P H-UV/ including A-APC- and PDC-SX

Fact:

• €185.000 euro more ink cost a year (H-UV)

Don’t panic yet!

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GL 840P H-UV figures:

Plate change A-APC versus APC

• 3540 plate changes a year:

APC: 251 hours

A-APC: 59 hours

= Savings 192 hours

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More productivity!

H-UV Make ready versus conventional

Conventional make ready

3540 x 34 min.= 2,006 hours

H-UV make ready

3540 x *20 min.= 1,180 hours

= Savings 826 hours

*Make ready time given by Nord imprim and DM Print (Both GL 840P HUV users).

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More savings…..of course! Maintenance H-UV vs conventional

Conventional given by K-station

on yearly base: 655 hours H-UV given by Nord Imp. and DB

print: 351 hours = Savings 304 hours

Maintenance includes: • Greasing • Cleaning (delivery etc ….) • Daily maintenance jobs by

operators.

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Looks better already!

• Savings A-APC/H-UV make ready/ Maintenance:

• Total savings 1,324hours.

Finished yet?...... of course not!

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Waste sheets!

Conventional make ready sheets 973.500 sheets (data K-station )

Faults due ink set off 125.000 sheets

Total: 1.098.500 sheets

H-UV make ready sheets: 513.300 sheets (N.I&DB 145 sh)

Savings: 582.200 sheets

Is this the only savings related to paper?

NOT AT ALL!!!

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PDC-SX and HUV advantage • PDC-SX advantage

– Read color bar in the middle of the sheet.

• Paper size 1 cm less in cumfrence! – H-UV advantage – No space needed for suction wheels!

• Paper size 2 cm less Lateral

• What does that mean in figures or sheets?

856.000 sheets

68.000 kg. (calculated 115 grs.)

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What about speed!

• K-station data LS 840P

conventional 11.739 s/h ( 2.307 hours) Normal for a Komori press

• But H-UV can run faster! Average 12.750 s/h. 27 Mili. Sheets= 2.117 hours savings 190 hours.

Do you want me to continue?

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LS840P GL840P

Plate change 251hrs 59 hrs Savings 192 hrs

Make-ready 2,006 hrs 1180 hrs Savings 826 hrs

Maintenance 655 hrs 350 hrs Saving 304 hrs

Wasted sheets 1,098,500 513,300 sheets Savings 582,200 sheets

Speed 11,700 sph- 2,037 hrs

12,750 s/hr 2,117 hrs Savings 190 hrs

Advantage H-UV/PDC-SX 0 856,000 sheets 68,000kg

Summary of all savings

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What is the end result?

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Facts!

Producing the same as a conventional printer on his LS840P in a year: He needs: 1512 hours less (€378,000 ) 1.438.000 sheets less (€68,000 ) TOTAL : €446,000 More cost ink: €180.000 BENEFIT €266,000 per annum

What does that mean in real production figures?

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Today and tomorrow!

• Today-LS840P

• Plate changes -3540

• Good copies -27 million

• Tomorrow-GL840P, AAPC, PDC-SX

• Plate changes-5740

• Good copies -33.5 million

CONVINCED? Well I am…….

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I REST MY CASE!

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KOMORI H-UV today!

H-UV is proven and can benefit your business.

Just listen to users in Europe to get an insight into its success.

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Questions?