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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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

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.

6.12 Retrofit UV wide belt transportation

Keep it movin’!

The wide belt conveyor table moves the printed sheets 
during the UV drying process with high precision to the 
next station. It is now the right time to optimise your 
production flow simply by retrofitting the UV conveyor 
table by a new wide belt transportation system. This new 
transportation system consists of only 4 instead of 5 belt 
tracks and includes new belts of significantly improved 
quality. By using wider conveyor belts, the edges of the 
sheets always fully rest on the surface of the belts. In that 
way a trouble-free sheet transfer is ensured at all times 
– no matter what sheet size or production speed you are 
running. The special properties of the newly developed 
belts reliably prevent the flaking of particulate matters 
that may contaminate the printed sheets. In addition, the 
new belts are FDA-compliant and food safe according to 
EU regulations 10/2011 and 1935/2004.

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.

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.

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.

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.

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.