People & Print. KBA RotaJET 76. Digital flexibility with industrial performance. Ko enig & Bauer AG

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1 People & Print KBA RotaJET 76 Digital flexibility with industrial performance Ko enig & Bauer AG

2 Major attributes KBA RotaJET 76 High-volume inkjet printing from the offset experts Changes in society and in the way society communicates have left the printing industry facing new challenges. These days, the use of electronic media and the digital exchange of data and information are an integral part of our everyday life. To counter this change, even very small print runs must be produced cost-efficiently, or specially tailored to specific customer groups. For 200 years Koenig & Bauer has driven innovation in the press manufacturing sector and played an active role in shaping the technological future of print. With the unveiling of our new and innovative RotaJET 76 digital inkjet press, developed in co-operation with the world's biggest print group and made in Germany, we are once again underlining this role. KBA stands for People & Print. We understand the market, we speak the language of generations of printers and understand the demands they place on systems, processes and final products. That is what makes us stand out from other suppliers in the emerging digital inkjet market. The name RotaJET is synonymous with quality, high performance and cost efficiency in the digital inkjet highvolume sector. It combines our unique know-how as market leader in highquality web presses with the wide-ranging expertise of a global print media giant. Against this backdrop, we have added a 2 KBA RotaJET 76 completely new dimension to the concept of high-volume inkjet systems. The KBA RotaJET 76 is a new web-fed inkjet press for high-quality digital print applications. It combines innovative precision engineering with highperformance hardware and software and cutting-edge piezo inkjet technology, making it the optimum industrial production tool for short print runs and personalised printing. Development of this press aimed at the digital print market focused on delivering above average performance, excellent colour and register stability, the ability to handle a wide

3 KBA RotaJET 76: major attributes Precision engineering for industrial demands High level of automation for greater productivity Flexibility for short print runs or personalised products Much smaller footprint than comparable presses Precise register thanks to intelligent web lead Superior piezo inkjet technology with variable droplet size Proven APPE-based native PDF workflow for high data throughput High output (max. 3,000 four-colour A4 pages/min) Excellent print quality (native print resolution 600dpi) Minimum waste and maintenance Superior paper logistics at and in the press Industry-standard JDF interfaces to third-party systems Individual inline/offline configurations supported Standing just under 10x4m, the KBA RotaJET has a significantly smaller footprint than comparable inkjet web presses range of stock, ease of operation, low maintenance, high availability and simple but effective workflow integration. But what ultimately sways the user is the total cost of ownership. Thanks to our experience in analogue press technologies, we understand industrial users and the demands they place on digital inkjet print. With our expertise, experience and frontline technology, we can provide the support and the tools you need to make a successful transition into the age of digital printing. Sheetfed Security Press technology for every scenario: with the launch of our own-brand, high-volume digital inkjet press we have expanded our extensive press range for different market sectors Commercial Metal-decorating Digital print Newspaper Packaging Coding KBA RotaJET 76 3

4 Features 4 KBA RotaJET76

5 Expertise based on longstanding experience Performance made in Germany KBA knows the print industry and its demands. Few manufacturers in the digital inkjet sector can compare with us when it comes to the know-how and in-depth experience in offset, flexo, gravure and security printing that we bring to the table. This is clearly showcased in the overall press complete with reel logistics, unwinders, printing units, embedded web lead, dryers, coaters and control and workflow integration, not to mention interfaces to third-party pre-press and post-press systems. Fast and reliable Engineered for a maximum web width of 781mm (30.74in), the KBA RotaJET 76 delivers maximum web speeds of 150mpm (500fpm) in four-colour production. The RotaJet's excellent performance, high reliability and stunning print quality on different substrates thanks to state-ofthe-art piezo inkjet heads and water-based pigment inks all combine to ensure a positive ROI. Excellent register accuracy The RotaJET 76 benefits from the experience of our KBA engineers with large web widths. Fitted with an ingeniously simple web lead without turning bars for four-colour production, KBA's first inkjet press sets a new benchmark. Used in conjunction with a large central impression cylinder, the precise web lead promotes precise web tension, which in turn delivers outstanding register accuracy. Prior to infeed in the second printing unit, ink and paper are gently dried in a compact and energy-saving infrared dryer. Small footprint Thanks to the intelligent web lead, the RotaJET stands a mere 9.6m (22ft 9in) long (excluding subassembly for inline finishing) and 3.9m(12ft 9in) wide considerably shorter and more compact than comparable rival press systems. Even the height of 3.35m (11ft 5in) has sufficient overhead clearance in most industrial premises. The compact design reduces walking distances for operators and enhances ease of use, waste levels and cost efficiency. Left: The compact RotaJET 76 combines innovative press engineering with powerful hardware, software and frontline piezo inkjet technology to create a flexible production tool for industrial digital print Right: The KBA IR dryer installed between the two printing units is extremely low-energy KBA RotaJET 76 5

6 Features 6 KBA RotaJET76

7 Technological excellence from the offset sector Synergy with digital technology Superior reel logistics The KBA reelstand with integrated and automated infeed was designed specifically for the RotaJET 76. It is considerably more robust than unwinders of comparable digital presses and is engineered to handle reels with a diameter of 1270mm (50in) and a max. weight of 1,300kg (2,860lb) and retrieve reel stubs with a diameter of 400mm (15.7in) from the floor without the need for any further equipment. Ease of use is further enhanced by the unwinder with infeed unit, which is fully embedded in the press control. The RotaJET 76 delivers features hitherto unique to the world of offset print. A motorised brake aids energy recovery, thus reducing energy consumption and costs. The subassembly is engineered for precise web tension and web guidance upstream of the infeed unit and the automatic infeed ensures fast and convenient web threading throughout the press. Another revolutionary feature is the optional connection to KBA Patras. This supremely practical reel-logistics system registers paper consumption, automatically determines residual quantities and ensures optimum control of reel logistics, thus allowing the RotaJET 76 to be fully embedded in an existing web offset environment. Further options include an automatic KBA reelstand and a rewinder. Above: The ingeniously simple web lead without turner bars enables four-colour printing on both sides of the web via two large central impression cylinders and is key to the outstanding print quality, low waste, ergonomic operation and small footprint of the KBA RotaJET Option: aqueous coater Prior to post-press, the printed substrate can be finished in one of our coaters, already well established in KBA offset presses, to protect the printed product against wear and moisture. This further enhances the quality of the product and allows printers to tap into new markets or applications, such as direct mail or personalised magazine covers. Left: The reelstand developed by KBA specifically for the RotaJET can pick up reel stubs with a diameter of 400mm directly from the floor Right: Time-saving automatic web-threading throughout the press via a conveyor belt (photo) is just one of the many unique features offered by the KBA RotaJET that makes it stand out from other inkjet web presses KBA RotaJET 76 7

8 Inkjet technology 8 KBA RotaJET76

9 Press manufacture and inkjet technology Focus on quality The KBA RotaJET uses frontline piezo inkjet technology that boasts four variable droplet sizes and an optimised screening algorithm. The two arrays of 56 inkjet heads each form an arch over large central impression cylinders for four-colour printing on both sides of the web, but can still be moved aside for cleaning and maintenance purposes. This arrangement provides for optimum web guidance and facilitates an outstanding print quality and register accuracy. The intelligent web lead without turner bars enables a contact-free web run. The inkjet heads in the RotaJET 76 are designed for heavy-duty use and contribute to the exceptional reliability of the overall system. Frequent replacement is avoided and uninterrupted industrial production is guaranteed. They are also extremely low-maintenance. Automatic cleaning can run parallel with other tasks, such as reel change or job preparation. Above: View from below of the array with 56 precisely stitched inkjet printing heads for four-colour printing on one side of the web This eliminates makeready cycles and enhances efficiency. The printing heads can produce good copies even during the start-up phase, which greatly reduces waste and speeds edition changes. Each of the 112 printing heads for fourcolour perfecting is individually controlled and each inkjet droplet hits the substrate at a precisely calculated spot. The inkjet heads are cleaned automatically, fast and reliably using a new methodology. It is well known that print quality depends on a number of parameters. In the KBA RotaJET 76, these parameters have been precisely co-ordinated to ensure that, whether your speciality is books, direct mail, commercials or advertisements, the RotaJET 76 meets all demands made on monthly output and achievable print quality. KBA RotaJET 76 9

10 Automation / workflow Data management Efficient workflow A powerful front-end and the KBA RotaJET 76 workflow are geared to the high data throughputs associated with industrial-scale PoD applications. With even the largest data volumes, the press delivers full-colour variable production at maximum speed, with no stoppages or delays. The RotaJET 76 workflow is based on APPE (Adobe PDF Print Engine), which can be scaled to suit your individual performance requirements. Press control and data management are module-based and embedded as standard to ensure fast commissioning. Designed to facilitate the work of the press crew, the PLC and dedicated drive technology are combined in a single control system and enable sophisticated functional sequences. The precision of the automatic web tension control is key to 10 KBA RotaJET 76 the consistently high print and register quality, while top-grade electrical and mechanical components ensure that the high level of automation is combined with reliable and energy-efficient technology. The software embedded in the system for job handling, control of the inkjet heads and colour management minimises the need for manual intervention, allowing the operator to concentrate on core tasks: the profitable production of high-quality digital inkjet products. Fast production start at the front-end XLO BOX

11 Consumables KBA Patras Ink and paper An expert partnership The RotaJET uses water-based inks with special surface-modified pigments. It delivers an outstanding print in near-offset quality. Print trials on book stock produced impressively clean and sharp prints of texts with negligible show-through. Even on offset substrates in four-colour production the results have been good. Above: A closer look at the supply technology of the KBA RotaJET 76, which uses water-based pigment inks Right: The KBA digital press produces good to very good results on a wide range of different stock KBA RotaJET 76 11

12 24/7 service Operation, maintenance and service From one expert to another The expertise of your personnel and press crew plays a key role in the success of your business in the digital print sector. We know how hard it is to find qualified staff, particularly when you're running a three-shift operation. So we have worked hard to make the RotaJET as intuitive as possible so that no matter who is operating the press, you are guaranteed the same high quality. It goes without saying that we offer your press crew indepth training prior to commissioning. The data screens, operating elements and press controls were designed by highly qualified engineers with longstanding experience in press manufacture and rigorously tested by practitioners in the industry. Our services include a 24/7 maintenance team and an online help team that can deal with the vast majority of problems quickly thanks to the RotaJET's remote diagnostics system. Even though the RotaJET's frontline inkjet and press technology requires significantly less maintenance than many other inkjet press systems, KBA offers a round-the-clock service team for your peace of mind 12 KBA RotaJET 76

13 KBA Post-press Patras Finishing Offline or inline Flexibility and product differentiation are essential in today's cut-throat market. The KBA RotaJET system supports tailored finishing and post-press solutions geared to your individual production scenario and target markets. If you want to use your post-press systems for different printing systems or you have a job structure that is extremely diversified the KBA RotaJET can be operated reel to reel. Alternatively, you can also link your online production to the post-press technology of longstanding KBA alliance partners. Folding, collecting, adding covers, binding, stitching, gluing, cutting, trimming and delivering the finished copies the RotaJET handles all the common production tasks normally undertaken by digital printing systems. Whether reel to reel or online with finishing we and our partners have the right solution for you. The JDF-compliant software for the RotaJET enables simple connectivity between pre-press, press and post-press, thus considerably enhancing integration options. Tell us about your production scenario our experts will be happy to analyse your process chain and help you choose the right pre-press and post-press systems for your press line and streamline your workflow. Inline production with the KBA RotaJET 76 and the SigmaLine digital post-press production system from Müller Martini at Drupa The SigmaLine with a SigmaFolder variable-format section folder module and Primera Digital gang-stitcher enables digitally printed magazines and advertising brochures to be folded and stitched inline. A number of SigmaLine systems are already in use in the digital book production sector KBA RotaJET 76 13

14 Investment planning The right business model Transparent and cost-efficient Technology, performance, print quality, operation, application options, workflow and service are all key topics in digital print. But with one aim: the optimisation of processes to maximise efficiency and profitability. On-demand or personalised production: the RotaJET 76 handles even the largest data volumes, delivering full-colour variable production at maximum speed, without stoppages or waiting times For your convenience we have developed a business model for the lifetime of the RotaJET 76. We also offer a range of transparent financing/leasing options tailored to your usage requirements, based on life-cycle costs and costs for service, maintenance and consumables, which can be coupled to your average monthly output, or to a more long-term goal if preferred. We are happy to meet your financial specialists and work out the most cost-efficient solution for your needs, regardless of whether you are new to digital printing or looking to expand. If you would like a demonstration of the KBA RotaJET 76, please feel free to contact us and we will be happy to help. Optimum access: the array of 56 printing heads can be moved aside for cleaning and maintenance work 14 KBA RotaJET 76

15 Specifications KBA Patras KBA RotaJET 76 At a glance Performance data Max. web speed: Web width: Print width: Cut-off length: Print volumes: Web lead KBA unwinder: 150mpm (500fpm) mm ( in) mm ( in) variable approx. 3,000 A4 pages/min, approx. 85 million A4 pages/month reel diameter: 1270mm (50in) max. automatic webbing up fully automated web tension control Printing heads Printing head technology: piezo electrically modulated DOD inkjet printing heads, fully automated printing head alignment Print resolution: 600 dpi native, quality plus due to 2-bit multi-level, variable droplet sizes Quantity: 56 printing heads per array, 112 total Stitching: automatic alignment of printing heads in array Ink system water-based pigment inks Dryer compact, energy-saving infrared dryer combined with the web being blown off with warm air Workflow/communications Consumption data Electricity: Compressed air: Cooling water: Exhaust air: Dimensions Length/width/height: Weight: Options Reel logistics: Coating: Remoistening APPE-based native PDF workflow JDF standard for press line intercommunication and integration of third-party systems (post-press) 100 kw (for typical four-colour production) connected load 50l/min (13gall/min) at 7 bar (no continuous use of compressed air) cooling capacity 20 kw 2500 m³/h (88,285ft 3 /h) (no after-treatment of exhaust air required) 9,600mm/3,900mm/3,350mm (standard 4/4, without rewinder or finishing) (22ft 9in/12ft 9in/11ft 5in) approx. 22,000kg (24.2 US tons) automatic reelstand with connection to KBA Patras reel logistics system dispersion coater No part of this publication may be reproduced in any way without the permission of Koenig & Bauer AG. Illustrations may depict special features not included in the basic press price. Subject to structural and/or technical modifications without notice. KBA RotaJET 76 15

16 The KBA RotaJET 76 from Koenig & Bauer AG For further information please contact our sales department at: Koenig & Bauer AG Web presses Postfach Würzburg, Germany Tel: +49 (0) Fax: +49 (0) Koenig & Bauer AG Sheetfed offset presses Postfach Radebeul, Germany Tel: +49 (0) Fax: +49 (0) /2012-e. Printed in Germany Our agency: Ko enig & Bauer AG