7.1 Burner control

Continuous flame monitoring safety system!

This new burner control replaces the now obsolete R 4341 and R 7241 models which are no longer available. The new burner control system conforms to all current safety regulations. The burner flame is constantly monitored by a self-monitoring system. An ergonomically designed display shows the latest operation status, error messages and the flame current signal thereby eliminating the need for a separate flame current gauge.

7.2 Steering plates for air circulation adjustment

Optimize your quality with simple air regulation!

The steering plates in the come up zone are moved to the optimum position to suit the size and weight of the sheets being produced. This ensures that the airflow across the sheet is ideal to produce the required curing profile without disturbance of the sheets which can result in scratching, sheet marking and spoilage. This upgrade can be delivered for all lengths of come up zone.

7.3 Spray lubrication system with PLC control

Pinpoint lubrication of the transport chain!

The automatic spray lubrication system guarantees pinpoint lubrication of the transport chain. A sensor monitors the exact positions of the chain links, and a PLC ensures precise metering of the oil drops to prevent waste attributable to over-lubrication. The lubrication system is supplied complete with all mechanical parts, a cabinet and a preset PLC controller, and can be installed very simply by the customer.

7.4 Burner KXB 2.0

Some like it hot!

Higher preheating temperatures represent new challenges to material and design. In order to meet the changed requirements, we have developed a completely new KXB 2.0 burner with a new type of cone. Thanks to its special design, the KXB 2.0 burner compensates for the greater heat, thus protecting the cone from damage. This means that the burner works at a consistent performance level. This in turn extends the service life and reduces the maintenance required.

6.1 Dynamic sheet control

Increase your product quality and line efficiency!

The dynamic sheet control system ensures completely slippage free and precise positioning of the sheets as they are transferred to the wickets. Even at the highest speeds the plate is held in the correct place using the latest vacuum technology and the rate of deceleration is finely controlled by means of a sensor and frequency controller system. The employment of a specially developed conveyor system and the latest belt materials results in the unit is virtually maintenance free.

6.2 Smooth transition loading ramp

Optimise your sheet transport!

Koenig & Bauer MetalPrint is offering a redesigned ramp kit for the loading machine of the wicket conveyor. This kit provides smooth damage free transition of the sheets from the pick up point into the LTG oven. The simple and precise adjustability of the ramps allows fine tuning of the transportation elements in front of the oven.

6.3 Dynamic sheet accelerator

Accelerate your production with power and quality!

As the cured sheet comes out of the drying oven it is essential that it is carried off the wickets quickly and consistently without damage. The dynamic sheet accelerator system achieves this by firmly gripping the sheet using the latest vacuum technology and then accelerating it under precise control out of the wicket area placing it in a consistent position on the outgoing conveyor. This has the advantage of reducing scratching and corner damage on the sheets as well as allowing the line to run reliably at higher speeds.

6.4 Vacuum sheet accelerator

Increase efficiency and quality!

The vacuum sheet accelerator provides precise, controlled, slippage free sheet transfer through the oven unloading machine ensuring that the sheets are accelerated to the correct line velocity. Even at high speeds, the sheet will be held in position by the specially developed vacuum conveyor system which employs the latest belt material resulting in very low maintenance.

6.5 Smooth transition unloading ramp

Optimize your sheet transport!

Koenig & Bauer MetalPrint is offering a redesigned exit ramp kit for their oven unloading machine. This kit provides smooth damage free transition of the sheets on to the discharge conveyor. The simple and precise adjustability of the ramps allows fine tuning of all transportation elements.

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.

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 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.

6.8 Pneumatic sheet alignment

In perfect rank and file!

The timed-action pneumatic sheet alignment device provides for precise positioning of the sheets before they are placed on the unloading machine. The device is adjusted by way of a hand wheel and clamping lever, with a corresponding scale to facilitate the desired setting. The alignment can also be set asymmetrically and is thus especially suitable for use with scroll sheets. In conjunction with a dynamic sheet accelerator (Upgrade 6.3) and an overhead brake in the stacker (Upgrade 6.6/6.7), pneumatic sheet alignment ensures exact, damage-free stacking of the sheets – an ideal prerequisite for improved downstream further processing.

6.9 Pneumatic transport chain tensioning

Tension, not strain! T

he original mechanism for transport chain tensioning involved chains and counterweights, and was very complex in design. Furthermore, constant readjustment was necessary during operation. A pneumatic cylinder can now replace this complex mechanism. The tensioning pressure is adjusted finely by way of a pressure regulator. The pneumatic cylinder guarantees constant power transmission to the chain tensioning lever and compensates variations in the operating conditions. The retrofit solution is simple to install in existing unloading machines.

6.10 Safety device with pneumatic lowering

Safety is what counts!

The existing safety device using cables and springs is replaced with a new transport unit comprising aluminium rollers and vacuum sheet accelerators with a separate motor drive. The new safety device is held in position or is swung downwards by a practically maintenancefree pneumatic cylinder. Line safety is further enhanced by sensor monitoring and fine adjustment by way of pressure regulators. This retrofit incorporates the pneumatic chain tensioning device of Upgrade 6.9.

6.13 + 6.14 Venturi sheet transportation for the loading and unloading machine-

There is something special in the air!

Within the metal decorating process, various sheet handling devices move the printed or coated sheets with high precision to the next station. When using conventional belt conveyor systems, flaking of particulate matters or residues of coatings may contaminate the decorated sheets. In addition, physical contact with belts and tapes 
may cause scratches on the sheets. Furthermore, sheet transportation via belts and tapes often cause minor displacements of the sheets; the consequence: unplanned machine stops and spoilage of sheets, especially within the critical area of the loading and unloading machine.

8.1 Feeder stack height sensor

Combine production security and quality!

The new height sensor detects the stack height on the rear edge of the top sheet and is carried out without causing any damages. The special geometry and sensor technology enables perfect stack level regulation and hence consistently sheet feeding in to the machine.

8.2 Kurvenscheiben aus Hochleistungskunststoff

Endurance runners!

Through the use of cams made of highperformance plastic for the vibrating suction unit and the roller pulse generator, the service life of the cams is increased and thus the productivity of the feeder improved. In many respects, cams made of highperformance plastic are superior to comparable components made of steel. In particular, the outstanding damping behaviour reduces the mechanical load significantly, especially with high-speed cams.

8.3 Electronic cam controller for controlling the suction unit and separating air

Minimise the maintenance needed for your metal sheet feeder!

The mechanical rotary piston for controlling the suction unit and separating air, with its wear-prone cams and roller switches, is replaced by a valve block. The valves are actuated by a preset electronic cam controller and an incremental angle encoder, which detects the exact position of the feeder. If required, the setting can be adjusted to production conditions on site.

8.4 Conversion kit for noise reduction

Noise damper!

Through the use of new noise-reducing air outlet nozzles, working around the feeder is now more pleasant. The compressed air and vacuum generators are also replaced to achieve further noise reduction. This significantly reduces noise exposure in the printshop – a contribution towards compliance with noise regulations. The new vacuum generator is also a dry runner, which means that oil check and oil change intervals no longer apply.

8.5 Continuous pile lift

Optimise your feeding operations!

Through the installation of the continuous pile lift, the distance between the top edge of the pile and the suction unit is always the same. This reduces jams in the feeder, because it becomes less likely that the front edge of the sheet should catch at the entrance to the feed table. The drive motor with mechanical brake is replaced by an inverter-controlled motor, which – in compliance with the provisions of directive DIN 13849 – also assumes the braking function.

8.6 Scroll side guides

Optimise your feeding operations!

The new side guides for scroll sheets allow free positioning of separator fingers and magnets to spread the pile of sheets. This allows optimum adjustment of the feeder to different types of sheet metal.

8.7 Stop & Turn pile lifting

Easy alignment of the pile of sheets!

Thanks to the installation of the new Stop & Turn pile lifting device, a pile of sheets that was not placed on the roller conveyor at right angles can subsequently be aligned. The pile of sheets is aligned with the front stop rails by means of an automated turning mechanism. It is no longer necessary to move the pile of sheets back and forth manually. Retrofitting is especially recommended for machines standing on a base, since this means that no foundation work is necessary.

8.8 Side blast air

Optimise your feeding operations!

Through the installation of side blast air nozzles, an air cushion is created between the plates at the front of the pile area. The improved separation of sheets reduces the number of jams, particularly in the case of sheets with high adhesion. The position of the nozzle can be adjusted laterally and in height.

8.9 Ultrasonic double-sheet detector

Ultrasonic double-sheet detector for the feeder – You better check!

High adhesion forces between metal sheets can lead to imperfect sheet separation and hence double-sheets at the infeed. The consequence: Expensive waste or even damage to the press and unplanned downtime.

8.10 Pneumatic package for feeder

Pneumatic package for feeder 770, 780 and 4050 – Let it flow!

At Koenig & Bauer, we are working continuously on innovations to further improve your printing and coating lines. With our hardware upgrades you stay up-to-date with the latest technological developments. In that way you continue to decorate metal sheets to the highest standards.

9.1 Koenig & Bauer ColorTronic – remote inking control system

Improve your quality and save time!

The new Koenig & Bauer ColorTronic remote inking control system eliminates the complex manual setting and readjustment of the ink zones. The printing staff saves the settings for each printing unit in the control panel and simply recalls this print job the next time. The result is a consistently high level of quality, as well as significant time savings when starting up production. The Koenig & Bauer ColorTronic consists of the central control panel with colour monitor as well as ISO lighting, electromotive ink zone adjustment and the complete ink duct with a ceramic-coated ink duct roller.

9.2 Motor-driven diagonal register

Remote adjustment of the diagonal register.

With the help of the remote-controlled diagonal register, the front lay can be motor-driven backwards and forwards by 0.25 mm to facilitate the setting up of the Mailänder printing presses types 122A and 222. This adjustment option is integrated in the existing display. In older presses, the controller may have to be retrofitted.

9.E1 Modern control and drive system

Electronics can also grow old!

The availability of spare parts for PS3/PS4 PLC controllers by Klöckner-Möller can no longer be guaranteed. The relevant software is not consistently supported either. With this upgrade, the PLC controller as well as the Synchro line synchronisation system will be converted to the latest Siemens S7 controller with Lenze drive technology, currently available worldwide. The display and operating system on each printing unit will also be modernised. In printing lines, a special PLC program developed by KBA automates the startup of the individual press functions. New technologies like remote maintenance will assist you during troubleshooting.

10.1 Pressure roller – simultaneous adjustment

Ease of operation and quality with one simple move!

The adjustment of the metering roller to the lacquering cylinder can be carried for both sides from the operating position by one person. Scale markings on the wheel produce a quick and accurate result without the need for hand tools. The old arrangement required adjustment by two people on the drive and operator sides of the machine.

10.2 Ball bearings for varnishing rollers

Enhance your quality and reduce your costs!

Replace the conventional high wear and high maintenance plain bearings on the varnish fountain and pressure rollers, with zero clearance precision ball bearings. This means that a more consistently even lacquer film weight is applied across the sheet thus reducing material costs and at the same time eliminating the needed for regular lubrication and maintenance of the old style bearings. Existing fountain and pressure rollers which are in a good condition can be reused following modification.

10.3 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.

10.4 Pneumatic scraper blade

Maximize the life of your scraper blade!

The mechanical scraper blade engagement system is replaced by two pneumatic cylinders. This allows the pressure between the blade and the impression cylinder to be kept constant through continual manometer measurement and fine adjustment system.

10.5 Pneumatic varnishing cylinder friction clutch

Excellent combination of production security and durability!

With the step-less pneumatic setting of the friction clutch the perfect slippage between varnishing and counter pressure cylinder can be achieved. The setting is easily carried out from the operator side via a manometer. The substitution of the mechanical gearing by a pneumatic clutch between the main gearing and the counter pressure cylinder greatly reduces maintenance costs.

10.6 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.

10.7 Solvent blade

A perfect solution!

The solvent blade removes a possible varnish layer from the counterpressure cylinder, particularly with highly pigmented, abrasive varnishes. A diaphragm pump pumps solvent into the holder, which is fitted with felt strips. This is pneumatically thrown onto the counterpressure cylinder to guarantee uniform contact pressure. The partially dissolved varnish is scraped off the counterpressure cylinder by an additional doctor blade, which is also pressed pneumatically, and fed into a collecting tank and reintroduced into the cleaning cycle. The result is that the back of the sheet is clean.

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.