Integrated Print Quality Control Systems

High intensity white LED

PQA-S V54,096 pixels

0.25 mm/pixel

Ink splashes, scumming, water splashes, oil splashes, hickeys and color variations etc.

Subject to sensitivity setting

Retains the most recent 100 jobs. 1,000 records/jobMonthly defect history data (monthly for a year)

1,000 jobs/month, 1,000 records job

Option

Option

1,024 pixels1.0 mm/pixel

High-frequency ignition fluorescent lamp

Ink splashes, scumming, water splashes, oil splashes, hickeys and color variations etc.

Subject to sensitivity setting

Retains the most recent 100 jobs. 500 records/jobMonthly defect history data (monthly for a year)

300 jobs/month, 500 records/job

-

-

PQA-S SG2,048 pixels0.5 mm/pixel

Maximum printing speed

-

Plain paper

-

Standard-

CameraResolution*1

Light sourceMax. inspection speedTarget defects

Target substrates

Defect history (XML file)

Color control*2

Automatic registration*2

PQA-W

*1 Acutal value depends on press model.*2 Must be selected when ordering.

26"~ 44"

3.0 mm (H) x 3.0 mm (W)

Anywhere on sheet (However, not within 10 mm of gripper edge)

Automatic measurement of registered locationsBetween colors and front/back printing position

ISO12647-2 [PSO], GRACoL,Japan Color

Standard equipment (switchable per job)

Spectrophotometer

L*a*b*, ∆E etc.20"~ 44"

3.2 mm (H) x 3.0 mm (W)

Within 38 mm of sheet edge

Handheld instrument

ISO12647-2 [PSO], GRACoL

Option

26"~ 44", Enthrone seriesUp to 6 colors

(single-sided presses other than Enthrone)Manual

3.5 mm (H) x 4.0 mm (W)5 mm (height) recommended

Gripper from sheet lead edge: 10–40 mmTail edge: 2.5–40 mm

Manual (removable measurement head type)-

ISO12647-2 [PSO], GRACoL,Japan Color

Standard equipment (switchable)

Densitometer

-20"~ 40"

Up to 6 colors (up to 4 colors for perfectors and SP machines)

Automatic3.2 mm (H) x 3.0 mm (W)

Within 38 mm of sheet edge

Handheld (option)

-

Option

ModelSensor headDensity control functionsColor control functionsCompatible modelsNumber of colors

Positioning on color barPatch size (minimum)

Color bar position

Spot measurement

Automatic registration

Defect history

Polarizing filter

Density, dot gain, trapping, contrast, hue error, grayness etc.

Up to 11 colors (up to 8 colors for perfectors and SP machines)

Automatic

PDC-SX PDC-SII PDC-SG PDC-LITE II

Model

Note:Copyright © 2016 Komori Corporation all rights reserved. All specifications stated herein are current as of March, 2016. Maximum printing speed may differ from specification herein. Komori reserves the right to change specifications on machines without notice and without obligation to modify equipment previously manufactured. Because of changes in design, specification, or optional attachments and accessories, the machine actually delivered may differ in appearance and performance from that shown in this brochure. The trademarks and logos of Komori Corporation or others used on this brochure are the property of Komori Corporation or their respective owners. Nothing contained in this brochure grants by implication, waiver, estoppel or otherwise, any right to use any trademark displayed on the brochure without the written permission of Komori Corporation or the respective owner.

KOMORI Print Management Solutions: Specifications

PQA Series Specifications

PDC Series Specifications

PMS en JPN 12P M21 4 Mar.2016 02K MP

32

OUTLINE

The Ultimate Answer to Short Runs and Quick Turnarounds

DigitalOnDemand through Coordination with Digital Technologies

The relationship between digital and IT technologies in the printing industry is growing

deeper and convenience is becoming ever more important. Komori’s new solutions have

offset printing as the core working in concert with digital printing and postpress.

20Matching Concept

KHS-AI (Advanced Interface)

KOMORI CMS Solutions

Start production printing within 20 sheets of print start-up

20Matching Concept and Color Management

20Matching is a Komori technology that transcends the standard perceptions of the offset

printing industry by matching standard colors within 20 sheets of print start-up. Komori has

developed the new Komori CMS Solutions to work together with the KHS-AI integrated control

system, a core Komori 20Matching technology. Komori CMS Solutions consist of three tools that

only a specialist press manufacturer like Komori could create. The first is K-PressNavi operator

support software for the stabilization of offset printing. The second is K-ColorChecker print

quality analysis software. And the third is K-ColorSimulator high-level color matching software,

which makes CMS proof setting tasks, that were complex and difficult up to now, extremely easy

for today’s workforce.

OffsetOnDemand

OffsetOnDemand is Komori's system to facilitate short runs and quick turnarounds by shortening

makeready time, cutting paper waste and reducing the printing process to the absolute

minimum while maintaining the high print quality and productivity of offset printing. The core

of Komori's revolutionary new OffsetOnDemand printing system is the fusion of the KHS-AI

integrated control system, the award-winning H-UV and the new leading edge Color Management

System. The result — OffsetOnDemand is the ultimate short run and quick turnaround solution

for today's highly competitive printing marketplace.

H-UV: Innovative Powderless UV Drying System

H-UV is the core technology of OffsetOnDemand. This is a revolutionary UV curing system that

enables instant curing using a H-UV lamp developed with Komori know-how and high-sensitivity

UV inks. H-UV enables immediate curing with just one lamp for each printed side of the sheet

and offers ecological and economic benefits as well as high quality and reliability.

KOMORI Products that Support OffsetOnDemandKOMORI Print Management Solutions

For OffsetOnDemand to enable short runs and quick turnarounds, the combination of PDC Series products and PQA

Series products that support digital control of print quality and high-level print quality control drives print process

optimization and dramatically raises productivity.

Series

Series

Optimization of Printing Tasks by Komori Products

Changeover/test printing

Series

Checking print quality

Series

Maintaining print quality

Printing tasks

For integrated control

For maintaining print quality

Series

Series Series

Series

For checking print quality

Integrated control system for Komori products that reduces paper waste, shortens makeready times, manages data and links various systems.

Checks standard print quality by digitizing colors and register.

Maintains print quality by inspecting quality and controlling colors.

H-UV Innovative Curing SystemInnovative System for Instant Curing

54

High Precision Preset Function(Self-Learning Function)Paper waste at print start-up is reduced to an

absolute minimum, makeready time is shortened,

and resources are substantially saved by

automatically analyzing and calibrating preset

data and optimizing color matching according to

changes in the machine, the printing

environment and printing materials.

Komori Offset Printing Press

Komori Web Offset Press

Automatic calibration using update results

Printing materials

Changes in environment

Paper gradePaper sizeFold specification

Air PresetsCentral management of all air control units in

the sheetfed press. Very effective in stabilizing

sheet feeding and delivery by making presets

that match the sheet size and thickness as well

as paper grade and grain.

Printing Task Optimization withKHS-AI as the CorePrinting task optimization can be advanced and

printing productivity can be greatly enhanced by

combining KHS-AI with PDC Series, for print quality

digitization, and PQA Series, for high-level print

quality control.

AI-Link(Integrated Control System for Web Offset Presses)Automatic control of fine adjustments at print

startup in addition to KHS-AI preset functions.

AI-Link provides integrated control of

peripheral devices in addition to control of all

units from the splicer to the folder.

These control synergies offer unprecedented

reduction of paper waste and extremely short

makereadies.

Self-DiagnosticsIn addition to managing the operating record, this

function provides graphs of trend data to assist in

understanding the press status. It also informs the

operator of press maintenance conditions. By

providing a self-diagnostic to prevent the

occurrence of problems, the system also helps to

minimize press down time.

KHS-AI (Advanced Interface)

Integrated Control for Shorter Makereadies, Less Paper Waste and Reduced Machine Down TimeKHS is an innovative productivity enhancement system developed to reduce job changeover time and paper waste

to an absolute minimum. The system uses job data from the MIS-linked K-Station and preset data from PCC, which is

linked to the CTP workflow. Plates output by a CTP system and preset data calculated from CIP4/PPF data enable

first-pull register accuracy and color matching. KHS-AI with self-learning is a further evolution of this KHS system.

Preset data is optimized by a self-learning function attuned to changes in the machine, the printing environment

and the printing materials.

On sheetfed presses, air and register adjustment preset functions — corresponding to the paper size, thickness,

grade and grain — ensure stable sheet feeding and delivery. On web offset presses, all tasks, including changes in

the fold specification, are automatically controlled, substantially reducing makeready time and paper waste. In

addition, the system manages job control, operation history and maintenance data and includes a self-diagnostic

function for troubleshooting.

A cylinder airCentral airAir above sheet release

Upper fan

5 air blows above pile

Suction drum

Decurler

Delivery air guide

Transfer cylinder air guide

Impression cylinderupper air

Sucker blowSucker vacuumSide lay

Suction boardFeedboardAir side layDriven front register lay

*Preset locations differ according to press specifications.

Web Press KHS-AI

Sheetfed KHS-AISmart FeedbackLinked to a PDC Series product, Smart Feedback

shortens color matching time and is very effective

in reducing paper waste by automating

everything up to formation of the ink film

thickness in the inker before printing and

providing conventional ink key opening feedback.

Density

Standard density

Target density

0 200 Number of copy100

Approximately 90 percent reduction of waste paper

Conventional FeedbackSmart FeedbackAutomatically replenishes

the necessary amount of ink before printing

Smart SequenceSmart Sequence is the ultimate short makeready

system, allowing the main makeready processes

from the end of one job to the start of the next

job to be started with just the touch of a button.

Virtually the entire makeready process is

accomplished automatically and seamlessly. This

reduces operator load and improves both print

quality and productivity.

1.Creation of job changeover data

5.Plate changing (Full-APC)

Smart Sequence start

7. Key presets

8. Web presets

9. Dryer heat-up

10. Pre-inking

6. Folder changeover

2.Ink removing

3.Blanket washing

4.Paper roll changing

2.Ink removing1.Finish

3.Blanket washing

4.Paper size and thickness

presets and air presets

6.Pre-inking and register presets

7. Test printing

8.Measurement by PDC-SII

9.Register adjustment

10. Production printing

5. Impression cylinder cleaning

plate changing (Full-APC)

Smart Sequence Operation Flowon Sheetfed Presses

ChillstandChillstand

Printingunit

Printingunit

SplicerSplicer

WebpathWebpath

FolderFolder

Komori-made

peripherals

Komori-made

peripheralsThird-partyperipheralsThird-partyperipherals

High QualityHigh ProductivityHigh Added Value

Short MakereadyCustomer Support

* Content of this catalog includes optional functions.

• Automatic register control• Dryer• Stacker-bundler

• Web guide• Cut-off• PQA-W

AI-LinkConcept schematic

PQA Series

PDC Series

LITHRONE Series+

KHS-AI

Pro

ductivity

Productivity enhancement by combinations of systems

76

Print Density Control Series

Series

PDC Series devices are systems that digitize the colors on printed sheets – previously adjusted and controlled by the

operator. Densities, L*a*b* and dot gain can be measured and recorded by scanning the color bar on the printed

sheet. When there is a difference from the target density value, the measurement results are fed back to the press

and the ink key openings are automatically adjusted. For color matching at print start-up in particular, changeover

time can be considerably shortened and paper waste can be significantly reduced by using the PDC device with the

Smart Feedback function linked to KHS-AI. Compatible with ISO 12647-2, the international print standard, the PDC

system is indispensible. A variety of models are available for a range of press configurations and needs.

Standardized Printing with Shorter Changeovers and Less Paper Waste

Spectral Print Density Control SX Model

High-end multifunction model with automatic registration functionPDC-SX adds an automatic registration function to the color control function so that both color and register are measured in one process and the information is automatically fed back to the press. For the color control function, an automatic X-Y travel system is used so that measurement can be performed regardless of the position of the color bar to maximize the image area of the sheet. On a perfector, the bar can be located in the center of the sheet to cut waste. In addition, spot measurement of particularly important points on the image is possible. The automatic registration function works by using special register marks so that register is measured together with color in the same scan and any adjustments are automatically fed back to the press.

Spectral Print Density Control SII Model

Komori’s best seller, with more than 2,500 units in operationPDC-SII scans the color bar on printed sheets and measures densities, dot gain, colors, and color differences and then displays the results in an easy-to-understand format on the display. The system is equipped with a function that feeds back to the press the amount of adjustment necessary as calculated from the density values whenever a change in densities occurs during printing. Since PDC-SII is spectral, it is capable of measuring special colors. In addition, spot assessment of densities and colors anywhere on the sheet during the run is possible with the handheld measuring instrument. The system also provides a printout of measurement results and makes it easy to produce materials for a report.

Spectral Print Density Control SG Model

High Cost Performance Model for Color ManagementPDC-SG control color by measuring the color bar on printed sheets when density feedback to the press is based on density and Lab measurements. If spot measurements are required, the scanning head can be easily removed from the track and used as a handheld unit.

Scanning Density Control System

Density control with easy operation at a low investment pointPDC-LITEII is a CMYK process color density control system that can be equipped on Komori sheetfed presses up to 40 inches in size. Since PDC-LITEII provides digital control of densities with easy operation at a low investment point, it is the ideal system as the first step on the way to genuine digital control of print quality. Equipped with a function that feeds back to the press the amount of adjustment necessary as calculated from the density values whenever a change in densities occurs during printing.

Color Management• Color feedback by means of density and Lab

measurements*1

• Spot measurement of critical points

• Accommodates color bar in the center of the sheet

by means of automatic X-Y travel system (PDC-SX).

• Compatible with ISO 12647-2, G7 and JapanColor

reports

*1 Color feedback by Lab measurement available only with PDC-SX.

Automatic Register Adjustment Function (PDC-SX)

• Color register feedback control

• Front/back register feedback control

• Image position on paper feedback control

• High precision measurement with Komori’s

register marks

* Control point depends on press specifications.

CMS CompatibleK-ColorSimulator 2

Using K-ColorSimulator 2, Komori’s own CMS

software, high level color matching between the

offset press and a range of printers can be

achieved simply by measuring the K-Color chart in

the margin of the printed sheet using a PDC

device. With a proof consisting of a simulation of

the offset printing colors that is output ahead of

time, waste in the color matching work at printing

can be considerably reduced.

* K-ColorProfilerII (optional) is necessary to measure the K-Color chart when using PDC-SII.

Printingsample

Printingsample

Registerfeedback

Summary of Functions

PDC-SX

••

Automatic

•26" ~ 44"

PDC-SII

Spectrophotometer

••

Handheld

-

20" ~ 44"

PDC-SG

••

Manual*1

-

26"~44" (single-sided, up to 6 colors)Enthrone Series

PDC-LITE II

Densitometer

•-

Optional

-

20" ~ 40"(up to six colors)

Function/model

Sensor head

Density control function

Color control function

Spot measurement

Automatic registration

Compatible models

*1 Removable measurement head type.* For detailed specifications, see the back cover.

Output of simulation of offset printing colors from printer by means of K-ColorSimulator 2

Matching of colors from start-up offset printing using standard densities with colors of printer

PDC-SX

PDC-SII

PDF Comparator System （PDC-SX option）A file comparator system that uses sensors to read the printed image for comparison with the originating pdf or tiff file data has been developed and may be specified with PDC-SX. This allows the operator to check for missing or added characters in the initial printing stage, preventing production losses.

98

PQA Series systems ensure high-level print quality control by inspecting all sheets in-line on the press according to

the same assessment criteria, checking for defects such as scumming, ink splashes, water drops, oil and ink spots,

hickeys and color variations. Previously the operator was required to check for these items visually by regularly

sampling printed sheets. When a defect is detected in the inspection, the operator is notified by a horn and a

warning lamp and the tape inserter or rejecter in the delivery is automatically activated, reducing the amount of

paper waste in printing and preventing defective sheets from being sent to postpress with the production sheets.

The lineup includes models suitable to the full range of press configurations and needs.

High-level Print Quality Control through In-line Quality Inspection

Print Quality Assessment System Series

Series

Print Quality Assessment System for Web

After the installation of an inspection system, inspection criteria are tightened and

many false detections are reported. Since this increases the operator’s workload,

the system is lacking in serviceability. When tolerances are relaxed, a major incident

eventually occurs due to major defects being overlooked. Komori confronted such

issues of conventional inspection systems head-on. PQA-W Print Quality Assessment

System for Web is the result of the unstinting infusion of Komori’s most advanced

technologies. False detections due to curving or expansion/contraction of the web

are slashed unconditionally, and high-efficiency inspection is assured by the

adoption of cutting-edge technologies.

Print Quality Inspection FunctionThe system enables the loading of an accurate

initial reference image using a high-precision CCD

camera and lens by means of advanced light

source control technology. Any difference found

by comparing the initial reference image with the

image on the printed sheet using Komori’s own

inspection algorithm is detected as a defect.

The inspection history data, such as detected image

data and defective sheet count, is saved in a

database and can also be monitored over the

network.

Press Interlock FunctionThe inspection process is extremely simple.

At job changeover, the system is linked to the job

data from KHS-AI, and the job name and printing

paper information necessary for inspection is

automatically set. Simple, automated operation is

assured by Komori’s total integrated system,

including the automatic start of inspection by a

link to the production sheet counter of the press

when production printing starts.

PQA-S V5color control screen

Color Control/Automatic Register Adjustment FunctionsIn addition to print quality inspection, the lineup

includes models that offer color control and

automatic register adjustment.

PQA-S V5

[Inspection/Color Control Model]

Print quality inspection + color control*1

[All-in-one model]

Print quality inspection + color control*1 +

automatic register adjustment

*1 Color patch system (located on gripper edge or in center)

In-line Print Quality Assessment System for Sheetfed

Advanced model meeting a wide range of needs

Includes automatic air control preset function based on sheet size, thickness, grade

and grain direction for stability at the inspection point. Komori software

compensates for individual problem sheets, further enhancing detection accuracy.

Specific areas of the sheet can be designated for different levels of inspection

sensitivity. Lineup includes Inspection/Color Control Model, providing print quality

inspection and color control, as well as All-in-One Model, providing print quality

inspection, color control and automatic register adjustment.

High Cost Performance Model for Color Control

Contributes to stable color and reduced paper waste by in-line measurement and

feedback to press. Simplicity of operation is achieved through coordination with

KHS-AI and other Komori systems.

Komori sheetfed offset press

Komori web offset press

Inspection results• Horn and indication lamp• Tape, marker• Delivery processes

PresetsJob information• Job name• Inspection permissible value setting• Paper information• Fold specification

Detection mode changed automatically according to press status• Start of production printing, blanket washing etc.

Sheet Numbering System/Automatic Mask Creation Software (PQA-S option)

The sheet numbering system that numbers each sheet on the feeder board and a

new system that accurately recognizes die-cutting data and facilitates quality

control in units of blanks has been developed and may be specified with PQA-S.

Also, PQA-S masking software that automatically creates the inspection area in

advance from the die-cutting data has been developed. This further strengthens

print quality control for packaging.

Sheet Numbering System

* Restrictions apply to models on which these systems can be installed and to combinations of models and functions.

Series

1110

As printing machines gain more functions and operations become more complex, the load on the operator

must be addressed. KID is an operation support system that puts together the information needed by the

operator and presents it at just the right time in an easy-to-understand format. KID makes it possible to

maximize the total performance of the press and achieve higher productivity. In addition, KID collects and

displays information from KHS-AI, PDC Series and PQA Series.

Support System with Optimized Information Presentation

Komori Info-Service Display

Press monitor

Display of printing image in actual dimensions

DoNet for Komori OnDemand

PCC converts digital data from prepress into a PQC-format ink profile for the

press. Using the preview image from CIP4/PPF data to calculate the area

ratio and presetting the ink keys with this accurate data has become

standard practice in the industry. PCC also converts PPF data and CMYK-TIFF

data into PQC ink key data for Komori presses.

PQC CIP Communicator

K-Station provides central control of multiple Komori presses and functions

as an interface to outside systems (such as the Management Information

System [MIS]). This facilitates sending/receiving production data by CIP4/JDF

and permits data management. K-Station receives the digital job ticket (*1)

from the MIS and passes it to KHS-AI. A digital job ticket (*2) is compiled

from KHS-AI data and sent as feedback to MIS.

Printing Task Control Software/JDF Interface

*1 Digital job ticket (Project name, job name, materials, image, estimated number of sheets, start and end times etc.)*2 Digital job ticket (Number of printed sheets, number of production sheets, number of waste sheets, operational status, start and end times etc.)

Building a Digital Workflow with the DoNet ConceptDoNet is a digital workflow concept centered on digital-ready, high-performance printing presses — the final output

device of printed items — based on the press manufacturer's viewpoint of supporting printing standardization. For

linkage with prepress and postpress equipment, Komori assures world-class JDF connectivity and conducts frequent

interoperability testing with systems from other manufacturers and vendors. This way Komori implements open

architecture thinking with the priority on users' operating environments.

Navigation system that supports standardization of printing

Print quality analysis software

Easy color matching software

Calculation of ink feed quantityTask standardization

Calculation of ink feed quantityTask standardization

Interface between internal and external systems

SeriesStandard print quality maintenance,

measurement and feedback

Series

Standard print quality inspection and control

Job information interfacePrint start-up by self-learning function

ICC profile creation software

Operation support system

VideoScope

* For detailed information, see the KOMORI CMS Solutions catalog.

To profit from ‘color,’ Komori’s Total Color Management based on real printing standardization

Easy color matching software

Simulation of offset printing with printer

Stabilization and standardization of printing

Navigation system that supports standardization of printingK-PressNavi is a completely new printing information tool that displays operating navigation to the press operator and supports standard printing operations in the printing plant.

Print quality analysis softwareK-ColorChecker is a color control tool that analyzes print quality and color matching from the PDC measurement results and automatically creates a report.

K-ColorSimulator 2 is the core system of the Komori CMS, providing simple high-level color matching between the offset press and various printers.

*