Overhauls & UpgradesUpgrades for your multicolour printing lines

1.1 Rear edge magnetic sheet separation1.2 Optimized feeder suction head1.3 Electromagnetic rear edge sheet separation system2.1 Printing cylinder sheet monitoring2.2 Pneumatic printing cylinder pressure on-/off switching2.3 Pneumatic rear edge sheet guide2.4 Side lay light barrier sensor2.E1 E-Modification3.1 Automatic suction head height setting3.2 Fine alignment vacuum valve3.3 Second vacuum valve impulse for fine sheet alignment3.4 Forwarding sucker control – feeder3.5 Feeder sheet separation4.1 Teflon®-coated ink duct4.2 Front lay sensors4.3 Gripper edge sensors5.1 Flexo scraping system5.2 VacuMatic belt infeed system5.3 Delivery with round belt5.4 Solvent blade5.5 Fine adjustment of the coating cylinder for the transverse recess6.6 MagStack magnetic overhead brake6.7 VacStack vacuum- operated overhead brake11.1 Remote maintenance service11.2 Overshoot detector11.3 Contact-free overpiling switch on the feeder11.4 Pneumatic sheet separator12.1 Additional sheet separation blowers MetalStar 3

1.1 Rear edge magnetic sheet separation

Combine quality improvement with production security!

Electromagnets are fixed on the infeed table and are clocked to lift the back edge of the sheet being fed, so ensures that the air blast system gives maximum sheet separation. This avoids scratching of sheets and existing coatings hence producing consistently higher quality, productivity. It also allows the consumption of com- pressed air to be reduced thus pushing down running costs.

The Advantages

  • Can be used on both scroll and rectangular sheets
  • Optimized sheet transport without damage
  • No adjustment necessary
  • Reduced compressed air consumption
  • Greatly improved sheet transport
  • Mainentance free

Your Benefit

  • Production flexibility, no setup times
  • Reduced spoilage costs
  • Time saving
  • Cost saving and noise reduction
  • Higher production speed
  • Lower production costs

 

Product informationen (PDF)

1.2 Optimized feeder suction head

Increase quality and productivity!

The optimized suction head allows higher printing speed combined with more accurate feeder sheet guidance, resulting in higher productivity and lower spoilage.

The Advantages

  • Increased production speed
  • Greater sheet feeding accuracy
  • Greatly improved sheet movement

Your Benefit

  • Higher productivity
  • Higher quality and hence satisfied customers
  • Minimization of sheet spoilage

 

Product informationen (PDF)

1.3 Electromagnetic rear edge sheet separation system

Excellent production security!

The electro magnets ensure that the air blast system can produce good sheet separation even on poor quality stacks. This ensures that the sheets are held uniformly, don’t stick together and the volume of compressed air needed can be reduced. It also allows pro- duction speeds to be increased with much smoother transpor- tation of the sheets resulting in greatly reduced spoilage.

Depending on the technical configuration of your equipment, we can offer a comprehensive consul- tancy service which will include supplying you with a quotation specifically tailored to your needs.

The Advantages

  • Consistent sheet feeding – even on poor quality stacks
  • Secure magnetic sheet separation
  • Automatic engagement as production starts
  • Reduced compressed air consumption

Your Benefit

  • Improved quality and higher production speed
  • Minimization of faults improving productivity
  • Assembly and forget
  • Cost and noise reduction

 

Product informationen (PDF)

2.1 Printing cylinder sheet monitoring

Maximize your production security!

Two additional sensors are fitted to each gripper system to continually monitor the sheets on the printing cylinder – in addition to those in the transfer drum area. Should a sheet get out of position, the machine goes in to a rapid stop condition which avoids major machine damage and loss of good sheets.

The Advantages

  • Protection against sheet loss
  • Rapid automatic switch-off

Your Benefit

  • Minimization of damage and reduced downtime
  • Minimization of sheet spoilage Increase of production speed and security

Product information (PDF)

2.2 Pneumatic printing cylinder pressure on-/off switching

Combine printing quality with production security!

The traditional electro- magnetic on-/off pressure switching of the printing cylinder is replaced by a pneumatic cylinder ensuring reliable synchronisation, constantly high printing quality and security of production.

The Advantages

  • Simple and secure function
  • Exact synchronisation of the printing cylinder on/off switching

Your Benefit

  • Highest production security
  • Minimization of downtimes
  • Increase of printing quality
  • Spoilage minimization

 

Prodckt information (PDF)

2.3 Pneumatic rear edge sheet guide

Combine quality and productivity!

The whipping of the rear edge of the sheet is avoided by the sheet guide in the transfer drum resulting in higher printing speed and quality combined with reduced spoilage.

The Advantages

  • Optimized transfer drum sheet guide
  • Rear edge sheet whipping and uncon- trolled contact with the leading colour cylinders is eliminated

Ihr Nutzen

  • Higher production speed
  • Improved quality and reduced spoilage

 

Product information (PDF)

2.4 Side lay light barrier sensor

Excellent production security!

The light barrier which checks the lateral sheet alignment can be used for most sheet configurations and the rapid action clamping system allows the feeder to be adjusted quickly. The system reduces the complications of sheet size changes and is not adversely affected by dirt.

Not retrofitable for machines with Zirconium feeders.

The Advantages

  • Fast repositioning of the feeder side guides via the rapid clamping system
  • Suitable for most types of sheets
  • Precise adjustment possible
  • Not affected by dirt

Your Benefit

  • Reduced change over times
  • No adjustment necessary when changing to scroll sheets / straight cut
  • Higher production security

 

Product information (PDF)

2.E1 E-Modification

Fountain of youth for your printing press!

In order to adapt your MetalStar 1 metal decorating press to current market re- quirements and to ensure a high level of availability in terms of productivity and the supply of spare parts, KBA-MetalPrint has developed a new press control system: E-Modification. This modern control console combines all of the functions of the press, the ink zones and the format adjustment in one Siemens S7 controller. The operating con- cept has been simplified and adapted to meet the needs of metal decorating. An easy-to-read touch display shows print- relevant setup data, for example of the damping unit, the ink zones and the duct roller speed.

This upgrade is suitable for all MetalStar 1 and MetalWing printing presses.

The advantages

  • Modern control system
  • Comprehensive fault messages
  • New job management
  • Remote maintenance

Your benefit

  • Simpler operation
  • High level of press availability
  • Help to remedy the fault quickly
  • Reduction of setup times
  • Assistance in troubleshooting

 

Product information (PDF)

3.1 Automatic suction head height setting

Production security by automation!

The stack height sensor registers the position of the stack top edge and sets the suction head to the ideal working position. During operation the suction head is continually levelled in a stepless motion to ensure that the distance from the suckers to the top of the stack is kept constant.

The Advantages

  • Automatical compensation of stack heights
  • Consistant sheet guiding
  • Avoids double and waste sheets
  • Maintenance free

Your Benefit

  • Minimization of set up time costs
  • Increasing of producivity
  • Higher processing reliability
  • Lower running costs

 

Product information (PDF)

3.2 Fine alignment vacuum valve

Increase your flexibility and productivity!

A pneumatic valve is moved by com- pressed control air to give fine alignment of the vacuum thus compensating for dif- ferent sheet types and quality.
This is a simple modification that can be fitted in one day.

The advantages

  • Increase of the switching security
  • Avoiding front edge damage of the sheet (thin & soft sheets)
  • Ideal processing of follow-up components
  • Maintenance free

Ihr Nutzen

  • Higher quality by ideal alignment of the vacuum for different sheet types
  • Higher quality – satisfied customers
  • Greater flexibility in the choice of sheet types
  • Improvement of productivity
  • Cost saving

 

Product information (PDF)

3.3 Second vacuum valve impulse for fine sheet alignment

Optimize the precision of your sheet re-register!

By a second impulse of the fine alignment vacuum valve, shortly before the grippers close, the sheet is fed again smoothly giving precise registration on the front lay mark thus sheet bounce back is corrected in the swing gripper unit.

The Advantages

  • Additional sheet alignment at the gripper end
  • Ideal for re-register operation
  • Maintenance free

Your Benefit

  • Increased productivity by improved machine security
  • Higher quality – satisfied customer
  • Cost saving

 

Product information (PDF)

3.4 Forwarding sucker control – feeder

Production security through ideal sheet feeding!

The rear forwarding suckers move inde- pendently from the front forwarding suckers by means of a modified mechani- cal control cam. This allows a precise transfer of the sheets from the separat- ing suckers to the forwarding suckers.

The advantages

  • Precise sheet separation and feeding
  • Optimized sheet monitoring
  • Maintenance free

Ihr Nutzen

  • Greater machine reliability
  • Improved productivity
  • Reduced costs

Product information (PDF)

3.5 Feeder sheet separation

Production security through enhanced sheet transportation!

The incoming sheet is lifted by a timed air pulse which ensures a smooth, virtually contactfree separation from the follow- ing sheet. The upgrade kit consists in the basic pneumatic parts and integrating software and may be retrofitted over one day.

The advantages

  • For both scroll and rectangular sheets
  • Positive sheet control with no sheet damage
  • Maintenance free
  • Less adjustment required

Your benefit

  • Highest flexibility with no change-over time
  • Consistent levels of production without spoilage giving satisfied customers
  • Higher quality
  • Reduced production costs – assembly and forget
  • Ease of operation

Product information (PDF)

4.1 Teflon®-coated ink duct

For all Sprint multi-colour printing machines

Minimize your change-over times!

The Teflon® coat minimizes the friction between the ink and the ink duct which produces a more even colour distribution within the duct and makes cleaning easi- er for the operator.

We can offer you a ink duct exchange system in which we supply refurbished Teflon® coated units in return for your old ducts.

The advantages

  • Teflon®-coated surface gives rapid cleaning
  • Reduction of solvent consumption
  • Improved colour distribution

Your benefit

  • Reduced change-over times
  • Reduced health risks for operator working conditions
  • Reduced material costs and environmentally friendly
  • Increased printing quality and reduction colour control adjustment time

 

Product information (PDF)

4.2 Front lay sensors

Increase your production flexibility and security!

Now, four active sensors instead of the previous two format-dependent sensors recognize the incoming sheet ensuring constant sheet monitoring.
As on each side, at least one sensor has to be covered, the system can handle a wide variety of scroll sheet formats and an improved sensor tech- nique enables the reliable recognition of pre-processed sheets.

The Advantages

  • Reduction in production stoppages by reliable sheet sensing
  • Four instead of two format-detection sensors
  • Recognition of low reflective sheets
  • Maintenance free operation

Your Benefit

  • Accurate sheet monitoring, higher productivity
  • High flexibility on the formats
  • Multiple use of waste sheets, Cost reduction
  • Cost saving

 

Product information (PDF)

4.3 Gripper edge sensors

Enhance your productivity and process reliability!

Sheet detection, irrespective of mate- rial and surface, is achieved by way of two inductive sensors. The stable sensor response serves to significantly enhance process reliability. The insensitivity towards dirt and simple cleaning ensure constant sheet travel and thus maximum productivity. Straightforward positioning and fast replacement permit considerable shortening of the press downtime.
The upgrade replaces the optical sensors used to date.

The advantages

  • Avoid production stoppages attributable to the sheet sensors
  • Reliable detection of the gripper edge, irrespective of material, surface or coating
  • No material-specific settings or calibration necessary
  • Maintenance-free
  • Simple cleaning

Your benefit

  • More stable sheet travel
  • Higher productivity and improved output figures
  • Waste sheets can be re-used; reduced costs
  • Ultimate flexibility and cost savings
  • Time savings

 

Product information (PDF)

5.1 Flexo scraping system

Reducing your set-up times!

The scraper blade is fixed into a quick clamp assembly which guarantees the fast replacement of a worn-out scraper blade. While production is running, the new blade can be fitted into the quick clamp support, which can be then inserted rapidly into the Flexo Scraping System blade holder during the next line stoppage.

Existing scraper blades can be reused following modification.

The advantages

  • Rapid scraper blade replacement
  • Considerably longer blade life
  • Faster bedding-in of the scraper blade
  • Reduced adjustment time

Your benefit

  • Time saving – higher productivity by minimization of set-up times
  • Greater line availability and lower spare parts costs
  • Shorter production start time
  • Simplified operation

 

Product information (PDF)

5.2 VacuMatic belt infeed system

The ideal combination of product quality and line efficiency!

With the VacuMatic belt infeed system, the sheets are carried slippage free by belts instead of the conventional chains. This guarantees absolutely consistent, silent, scratch-free sheet transportation and eliminates the old complex length format setting process.
As chain systems are no longer employed, any chance of oil contamination on the sheets is avoided and maintainence costs are greatly reduced.

The advantages

  • Consistent, absolutely scratch-free silent sheet transportation
  • Precision registration on spot coated sheets
  • No length format setting necessary
  • Use of belts instead of chains
  • No lubrication necessary
  • Optional format setting

Ihr Nutzen

  • Higher quality, low noise environment
  • Reduced lacquer consumption
  • Reduced set up time
  • Vastly reduced sheet damage and noise
  • Contamination free sheets
  • Minimiziation of set up times

 

Product information (PDF)

5.3 Delivery with round belt

A clean solution!

The use of round belts reduces the con- tact surface of the metal sheets, thus minimising dirt accumulation through varnish residues on the belts.

This upgrade is suitable for the following coating machines:

Type 4040 coating machines: All series
MetalCoat 470: From machine no. 470-001 up to and including 470-091

The advantages

  • Less varnish residue on the round belts compared to flat belts thanks to the reduced contact surface
  • Reliable sheet transportation through reduced contact surface
  • Simplified operation with lateral adjustment of the guide rollers for changing formats, compared to flat belts

Your benefit

  • Fewer impurities on the undersides of the sheets through reduced con- tact surface and fewer contact points
  • Stable sheet transportation
  • Reduction of setup times when changing formats thanks to easier operation

 

Product information (PDF)

5.4 Solvent blade

A perfect solution!

The solvent blade removes a possible varnish layer from the counterpressure cylinder, particularly with highly pig- mented, abrasive varnishes. A diaphragm pump pumps solvent into the blade cham- ber, which is fitted with felt strips and the doctor blade. This is pneumatically thrown onto the counterpressure cylinder to guarantee uniform contact pressure. The partially dissolved varnish is scraped off the counterpressure cylinder by the additional doctor blade, fed into a col- lecting tank and reintroduced into the cleaning cycle.

To clean and replace the felt strips and the doctor blade, the complete blade chamber is removed from the side of the press.

This upgrade is suitable for all 4040, 470 and 480 type coating presses.

The advantages

  • No varnish residue on the counter- pressure cylinder or on the backs of the sheets
  • Reduced wear on the main scraper blade
  • Easy replacement of the complete doctor blade unit
  • Simple operation and adjustment since the solvent blade is thrown on pneumatically

Your benefit

  • Improvement in quality – less waste
  • Longer service life
  • Optimised set-up time

 

Product information (PDF)

5.5 Fine adjustment of the coating cylinder for the transverse recess

Ideal solution!

The fine adjustment of the circumfer- ential register serves to position the transverse recess of the coating cylin- der exactly. The two friction discs are replaced by two toothed adjustment wheels. This eliminates the slip, and exact positioning of the coating cylin- der, down to 0.1 mm, is possible straight away. There is no further need for any repeated, time-consuming corrections.

This upgrade is suitable for all 4040 and 470 type coating machines.

The advantages

  • Fast, reliable adjustment of the circumferential register
  • No slip by the coating cylinder during adjustment
  • Exact setting through toothed adjustment wheels

Your benefit

  • Shorter set-up times
  • Exact position of the transverse recess – higher quality

 

Product information (PDF)

6.6 MagStack magnetic overhead brake

Quiet efficiency to the end of the line!

With the magnetic overhead brake, the metal sheet is brought to a controlled stop from full production speed, and falls vertically and precisely onto the pallet.
The deceleration process is controlled by a frequency converter with suitable software in a separate cabinet, as well as light barriers and sensors. As the new system does not use the spring-loaded sheet buffers and the stacker fan, the system is practically maintenance-free.

For LTG single and double stackers types 217 (except non-stop version), 803 and 804.
Version for special formats available on request.

NEW: Now also for both boxes

The advantages

  • Damage-free stacking in both boxes now
  • High production speed
  • Quiet and precise stacking
  • Especially suitable for scroll sheets and for thin sheets
  • Less adjustment required

Your benefit

  • Increased quality, especially when reusing the sheets in high- performance lines
  • Cost reduction through minimisation of spoilage
  • Time savings – higher productivity
  • Improved working conditions through compliance with noise regulations
  • Greater flexibility and production depth
  • Simpler operation

 

Product information (PDF)

6.7 VacStack vacuum- operated overhead brake

Damage-free stacking of tinplate and aluminium sheets!

With the vacuum-operated overhead brake, the metal sheet is brought to a controlled stop from full production speed, and falls vertically and precisely onto the pallet. The vacuum-operated overhead system is suitable for aluminium and tinplate sheets.

The deceleration process is controlled by a frequency converter with suitable software in a separate cabinet, as well as light bar- riers and sensors. As the new system does not use the spring-loaded sheet buffers and the stacker fan, the system is practi- cally maintenance-free.

Suitable for LTG single stacker in the welded frame version (year of construction up to approx. 1994) and in folded steel plate version (year of construction from approx. 1994). On request.

The advantages

  • Suitable for aluminium and tinplate
  • Damage-free stacking
  • High production speed
  • Specially suitable for scroll sheets
  • Less adjustment required

Your benefit

  • Flexible, independent production
  • Increased quality, especially when reusing the sheets in high- performance lines
  • Cost reduction through minimisation of spoilage
  • Time savings – higher productivity
  • Greater flexibility and production depth
  • Simpler operation

 

Product information (PDF)

11.1 Remote maintenance service

Worldwide rapid cost-saving support.

The advantages of our remote main- tenance service are comprehensive and quick diagnosis, extremely quick response time and significantly lower costs compared with an on-site service.

Remote maintenance service via the internet replaces the conventional solu- tion of technical support via modem. This offers a worldwide availability through state-of-the-art technology and, as a result of quicker and more sta- ble data transfer, an even more efficient technical support is provided.

A router is integrated in the machine control panel and, after an exchange of keys, it provides the connection to the central Koenig & Bauer server via your company network and the internet.

We guarantee the required safety standards:

  • Clear identification system
  • Firewall
  • Encription

Installation and start-up can be done within one day. This solution will be standard equipment on all new machines.

The advantages

  • Data transfer via state-of-the-art technology
  • High connection speed, time-saving diagnosis
  • No additional telephone lines required
  • Standardised technique

Your benefit

  • Simple communication with a secure connection
  • Shorter downtime hence higher productivity
  • Cost savings
  • Worldwide availability

 

Product information (PDF)

11.2 Overshoot detector

Additional sensor for detecting early sheets.

The overshoot detector monitors the gap between the previous and the following sheet by means of a photo sensor on the feeder table. If this gap is not detected, this is recognised by the sensor as an early sheet, and the press stops with a fast stop (emergency stop).

After the early sheet has been removed and the error message reset, the press can be restarted and the print job continued.

This upgrade is suitable for all MetalStar 2 type presses.

The advantages

  • Reliable detection of early sheets
  • Prevention of crashes, as the printing press is stopped in time
  • Prevention of major damage in the region of the feed drum

Your benefit

  • Increased production reliability
  • Prevention of unnecessary downtimes
  • Prevention of unnecessary repairs

 

Product information (PDF)

11.3 Contact-free overpiling switch on the feeder

Contact-free and wear-free!

The feeder of the MetalStar 2 was origi- nally equipped with a mechanical and maintenance-intensive overpiling switch. This upgrade replaces this switch with a contact-free ultrasonic sensor.

The switching position is infinitely adjustable using a teach-in procedure. A safety limit stop switch to protect the suction head is mounted outside the sheet path.

This upgrade is suitable for all MetalStar 2 type presses.

The advantages

  • Wear-free
  • Contact-free
  • Easy installation

Your benefit

  • Reduced maintenance
  • Reduction of costs for spare parts
  • Prevention of downtimes
  • Low installation costs

 

Product information (PDF)

11.4 Pneumatic sheet separator

Greater production reli- ability through enhanced sheet transportation!

The incoming sheet is lifted by a timed air pulse which ensures a smooth, virtu- ally contactfree separation from the fol- lowing sheet.

The upgrade kit consists of pneumat- ic parts and integrating software, and can be retrofitted within one day. This upgrade is already being used by many customers, and has proved to be highly successful.

This upgrade is suitable for all MetalStar 2 type presses.

The advantages

  • Stable transportation of scroll, rectangular and aluminium sheets
  • No damage to the sheets – low waste
  • Simple handling

Your benefit

  • High degree of production flexibility
  • Reduced costs
  • Less adjustment required

 

Product information (PDF)

12.1 Additional sheet separation blowers MetalStar 3

A fresh breeze for your business!

A stable and accurate transfer of sheets from the feeder pile to the first printing unit determines the print quality with regards to the feed and transfer register. With additional lateral separation blowers at the rear and front pile corners, the sheet separation in the feeder can be significantly improved. Additionally, extra strong permanent magnets fan out the rear edge of the sheets. At the same time, a pneumatic sheet clamping device prevents the sheets from getting stuck at the magnets.

This upgrade is suitable for all MetalStar 3 type presses.

The advantages

  • Optimised sheet separation
  • Stable sheet transfer with less machine stops

Your benefit

  • Shorter make readies for material change
  • Favourable price

 

Product information (PDF)

Feeder MetalStar 1
MetalWing / MetalStar 1
Feeder 790
Sprint
Coating 4040/470/480
Sheet Handling
MetalStar 2
MetalStar 3
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