H-UV Expert Session - Принт енд Пъблишинг ... · PDF file H-UV printing...
92
www.komori.eu H-UV Expert Session 1
Transcript of H-UV Expert Session - Принт енд Пъблишинг ... · PDF file H-UV printing...
www.komori.eu
H-UV Expert Session
1
www.komori.eu
Komori H-UV
An Eco-friendly application taking process to new levels of efficiency
www.komori.eu
1. The origins of H-UV.
2. Why we developed H-UV.
3. What is H-UV?
Komori H-UV
www.komori.eu
www.komori.eu
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.
www.komori.eu
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
www.komori.eu
WHY WE DEVELOPED H-UV
www.komori.eu
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’
www.komori.eu
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!
www.komori.eu
WHAT IS H-UV
www.komori.eu
What is H-UV
Development of a unique lamp with unique wavelength.
Ink with specially developed photo initiators.
Combination of tested and certified products.
www.komori.eu
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!
www.komori.eu
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.
www.komori.eu
The Future!
• Speed up the manufacturing process.
• Reduce production cost.
• Broaden your market possibilities.
• Improve margins.
www.komori.eu
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.
www.komori.eu
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’
www.komori.eu
H-UV benefits
A real alternative to conventional printing.
An application that increases your product quality, productivity and truly benefits your business.
www.komori.eu
H-UV ink
Advantages for conventional and UV printers
18
www.komori.eu
hubergroup H-UV inks
Advantages for conventional and UV printers
Printology H-UV Reto Andres
www.komori.eu
Resins Oils Dry ink film
Resins Oils
Penetration
Evaporation
Conventional drying
Drying mechanism
www.komori.eu
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
www.komori.eu
Advantages UV offset
• Fast curing
• Inline finishing
• High chemical, mechanical resistances
• Highest gloss levels (OPV)
• Non absorbing substrates
• No spray powder
www.komori.eu
UV
dry ink film oligomers monomers
photoinitiator
UV curing
Drying mechanism
www.komori.eu
Electromagnetic spectrum
www.komori.eu
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
www.komori.eu
Is H-UV able to improve conventional and UV offset printing?
- Drying - Carbonating - Need of varnishing - Other benefits ? - Areas of usage ?
www.komori.eu
Drying / Curing differences
Standard UV ink H-UV ink
No spray powder needed !
No dependency on different substrates (water/oil absorption)
www.komori.eu
conventional Non UV ink
Standard UV ink
Carbonating differences coated paper
H-UV ink
=> Lowest carbonating with H-UV => No varnish needed !
www.komori.eu
oilbased
Print quality on uncoated offset paper
H-UV
=> More contrast => Brighter colours => Bigger gammut
=> Less ink consumption
www.komori.eu
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
www.komori.eu
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
www.komori.eu
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
www.komori.eu
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
www.komori.eu
H-UV drying
34
www.komori.eu
H-UV Drying
• Printing & Drying
– Drying technology
• H-UV Technology
– Power Consumption
– Efficiency
– Going Green
35
www.komori.eu
www.komori.eu
PRINTING & DRYING
Sheetfed dryers - options
www.komori.eu
Best technology available (Application vs. technology)
conventional
Sealer / Coating
Ink only
UV Offset
High Gloss Coating
Special Substrates
www.komori.eu
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
www.komori.eu
Where does H-UV fit?
H-UV
conventional
Sealer / Coating
Ink only
UV Offset
High Gloss Coating
Special Substrates
www.komori.eu
Example: 5Colour + Coater
Conventional + wb coating
UV offset + UV coating
H-UV + H-UV coating
www.komori.eu
DRYER - TECHNOLOGY
Let‘s have a look behind it
www.komori.eu
Example: 5Colour + Coater
Conventional + wb coating
UV offset + UV coating
H-UV + H-UV coating
www.komori.eu
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
www.komori.eu
Example: 5Colour + Coater
Conventional + wb coating
UV offset + UV coating
H-UV + H-UV coating
www.komori.eu
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
www.komori.eu
Example: 5Colour + Coater
Conventional + wb coating
UV offset + UV coating
H-UV + H-UV coating
www.komori.eu
H-UV TECHNOLOGY
Let‘s step back and explain in detail
www.komori.eu
Radiation
H-UV
www.komori.eu
H-UV Dryer
H-UV lamp head
– Ozone free lamp
– Higher efficiency
– Less heat
– Built in Active Power Control (APC™)
www.komori.eu
Efficiency
less energy, MORE Curepower
Matching of Components
H-UV Lamp
Electrical Control
www.komori.eu
Sounds magical…
www.komori.eu
H-U Lamps (K-Supply )
• UV lamp manufacturing
• Design
• Manufacturing
In house with equipment manufacturing unit
www.komori.eu
Magic? – Science!
STANDARD
QUARTZ
QUARTZ
used for H-UV bulbs
Special metal halide „doping“
Original H-UV represents most advance technology
www.komori.eu
H-UV bulb
Special lamp with tuned output: => Reducing Energy requirement by 66%
www.komori.eu
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
www.komori.eu
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
www.komori.eu
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
www.komori.eu
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
www.komori.eu
Green Printing
Going green without worries • IPA free Print • Min. power consumption • Preserving the touch of paper • Safe for immediate post press handling
www.komori.eu
Thank you for your attention! Uli Sause – Baldwin Technology
www.komori.eu
Printology H-UV
Tony Carter
An Eco-friendly application taking process to new levels of efficiency.
www.komori.eu
www.komori.eu
H-UV Sheet-fed sales 68 sheet-fed presses
2
8
2
4
4
7
2 2 1
2
3
2
1
1
2
27
www.komori.eu
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.
www.komori.eu
On demand market
Efficient production requirements.
High quality control, standards.
H-UV reduces material cost and increases available production time.
www.komori.eu
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
www.komori.eu
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.
www.komori.eu
WHAT ARE THE REAL BENEFITS TO YOU.
www.komori.eu
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.
www.komori.eu
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!
www.komori.eu
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
www.komori.eu
Production comparison
Komori LS 840P conventional
vs
Komori GL 840 H-UV
www.komori.eu
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
www.komori.eu
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
www.komori.eu
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
www.komori.eu
Customer request!
• H-UV Technology
• More productive
• Better quality
• Less maintenance
• Less paper consumption
• Less fault percentage
• Diversification
• Added value
• Figures…………..
Which configuration?
www.komori.eu
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!
www.komori.eu
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
www.komori.eu
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).
www.komori.eu
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.
www.komori.eu
Looks better already!
• Savings A-APC/H-UV make ready/ Maintenance:
• Total savings 1,324hours.
Finished yet?...... of course not!
www.komori.eu
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!!!
www.komori.eu
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.)
www.komori.eu
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?
www.komori.eu
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
www.komori.eu
What is the end result?
www.komori.eu
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?
www.komori.eu
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…….
www.komori.eu
I REST MY CASE!
www.komori.eu
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.
www.komori.eu
Questions?
