9_Komori-1

H-UV Expert Session

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Komori H-UV An Eco-friendly application taking process to new levels of efficiency

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Komori H-UV 1. The origins of H-UV. 2. Why we developed H-UV. 3. What is H-UV?

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The origins of H-UV • Seven years ago we were evaluating curing systems. • Benefits but many negatives. • Maintain the benefits and get rid of the negatives. • Develop with partners a new way of drying and new type of inks.

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The Origins of H-UV • Many hours in development and testing. • Ensuring the recipe worked time after time. • The Return on investment ROI had a solid platform. • Why? Many false applications in the past

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WHY WE DEVELOPED H-UV

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Why we developed H-UV. • A constant drive for process efficiency. • Constant battle to maintain competitive edge. • Manufacturing requires innovation to progress. • Komori has a 30 year history of innovation.

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Press room efficiency

People Process

Technology

…Each leg is important independently but each is reliant on the strong support from the other two legs’

Why we developed H-UV.  Compete with digital  High cost of materials.  Printing on difficult substrates.  Print On demand requirements.  A constant battle to maintain a status quo!

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WHAT IS H-UV

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What is H-UV  Development of a unique lamp with unique wavelength.  Ink with specially developed photo initiators.  Combination of tested and certified products.

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What is H-UV ? • H-UV is a combination of NEW Technology and utilizing tested and selected products • Developed by KOMORI and only available from KOMORI • H-UV is Unique!

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Conventional offset printing. • The ink emulsion dilutes into substrate. • Difficult to print on absorbent substrates. • Requires a combination of methods to speed up manufacturing. • Spray powder. • Water based varnish, IR/Hot air. • Standing time. www.komori.eu

The Future! • Speed up the manufacturing process. • Reduce production cost. • Broaden your market possibilities. • Improve margins.

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H-UV printing. • The ink dries on the surface. • Very little absorbency • Higher gloss levels especially on low grade papers. • No ‘dry back’ therefore uses less ink. • Allows immediate finishing. • Allows immediate reverse printing. www.komori.eu

H-UV printing     

Reduced initial cost Low Heat generation Ozone free production Environmentally friendly Carton board printing possible  Plastic printing possiblel

‘A system which can cure ink quickly using just one ozone-free UV lamp’ Yellow Magenta Cyan

One H-UV lamp

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Black

H-UV benefits  A real alternative to conventional printing.  An application that increases your product quality, productivity and truly benefits your business.

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H-UV ink Advantages for conventional and UV printers

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hubergroup H-UV inks

Advantages for conventional and UV printers

Printology H-UV Reto Andres www.komori.eu

Drying mechanism Conventional drying

Evaporation Resins Oils

Resins Oils

Penetration

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Dry ink film

Problems with oilbased conventional inks 1 – uncoated offset papers => very slow drying, low piles => depending of water-/oil absorption of substrates 2 – non-absorbent substrates => very slow drying, low piles => Usage of spray powder

3 – coated offset papers => more and more rub, carbonating issues => varnishing necessary => Usage of spray powder

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Advantages UV offset • • • • • •

Fast curing Inline finishing High chemical, mechanical resistances Highest gloss levels (OPV) Non absorbing substrates No spray powder

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Drying mechanism UV curing

UV

oligomers monomers photoinitiator

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dry ink film

Electromagnetic spectrum

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Spectrum mercury UV – H-UV lamp Depth curing Adhesion Opaque white

Depth curing Adhesion Pigmented inks

Surface curing UV varnishes 100. 0

Heat formation

Ozone formation

90.0

80.0

70.0

Inks and varnishes must be adjusted to the lamp spectrum !

60.0

50.0

40.0

30.0

20.0

10.0

0.0 200

260

320

Wave length [nm]

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380

440

Is H-UV able to improve conventional and UV offset printing?

-

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Drying Carbonating Need of varnishing Other benefits ? Areas of usage ?

Drying / Curing differences

Standard UV ink

H-UV ink

 No dependency on different substrates (water/oil absorption)

 No spray powder needed !

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Carbonating differences

coated paper

=> Lowest carbonating with H-UV => No varnish needed !

conventional Non UV ink

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Standard UV ink

H-UV ink

Print quality on uncoated offset paper

H-UV => More contrast => Brighter colours => Bigger gammut

=> Less ink consumption

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oilbased

Possible applications / Benefits of H-UV inks On uncoated substrates: • More contrast • Brighter colours • Bigger gammut • Less ink consumption (up to 30%) General: • Better drying/curing • No need of spray powder • No varnishing needed • Less temperature impact (plastics) • Inline effects / finishing • Less energy consumption

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Commercial

Packaging

Available ink series for H-UV NewV set KHS (high sensitive) Uncoated, Coated papers / boards

NewV poly KHS (high sensitive) Metallised papers/boards, Plastic films

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Consumables Ink EUR/kg Dispersion varnish EUR/kg Varnish H-UV EUR/kg Spray powder EUR/kg Energy cost EUR/kWh Replacement HUV bulb EUR/piece

Conventional 8.00 1.50 7.00 0.14

HUV 15.00 16.00 0.14 600.00

Consumables consumption Ink kg/year Dispersion varnish kg/year Varnish H-UV kg/year Spray powder kg/year Energy kW/h Energy consumption per year Lifetime H-UV bulb

Conventional 1'800.00 5'500.00 360.00 58.00 189'312.00 -

HUV 1'620.00 0.00 20.00 65'280.00 750.00

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Working times Daily working time (2 shift) in h Working days per year => h per year Cost per working hour

Conventional 13.60 240.00 3'264.00 290.00

HUV 13.60 240.00 3'264.00 290.00

Annual cost calculation Inks Dispersion varnish Varnish H-UV Spray powder Energy Replacement H-UV bulbs Total costs

Conventional 14'400.00 8'250.00 2'520.00 26'503.68 51'673.68

HUV 24'300.00 0.00 10'053.12 2'611.20 36'964.32

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H-UV drying

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H-UV Drying • Printing & Drying – Drying technology

• H-UV Technology – Power Consumption – Efficiency – Going Green

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Sheetfed dryers - options

PRINTING & DRYING

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Best technology available Ink only

Sealer / Coating

conventional

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Special Substrates

(Application vs. technology)

High Gloss Coating

UV Offset

Drying principles / options Absorption

Evaporation

Curing

Slow process

Accelerated drying

Kick-started chain reaction

No Dryer

IR & HA Dryer

1 day

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79kW

UV Dryer EOP + 1

>90kW

Where does H-UV fit? Ink only

Sealer / Coating

Special Substrates

conventional H-UV

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High Gloss Coating

UV Offset

Example: 5Colour + Coater Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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Let‘s have a look behind it

DRYER - TECHNOLOGY

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Example: 5Colour + Coater Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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IR/HA Power Consumption What for: Effect: Costs:

IR lamps boosting temperature of paper and water evaporation of water born materials 52kW

What for: Effect: Costs:

Hot Air for boosting ambient temperature in press Creating environment to absorb water vapour 18kW

What for: Effect: Costs:

Exhaust enabling Air exchange Removing hot, damp air to keep process going 9kW

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Example: 5Colour + Coater Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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UV Power Consumption What for: Effect: Costs:

UV lamp creating radiation broad exposure of radiation to the sheet 71kW

What for: Effect: Costs:

Exhaust to atmosphere Removing ozone contaminated air to atmosphere 7kW

What for: Effect: Costs:

Water Cooling Cooling of dryer parts in press to protect from overheating 12kW

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Example: 5Colour + Coater Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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Let‘s step back and explain in detail

H-UV TECHNOLOGY

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Radiation

H-UV

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H-UV Dryer H-UV lamp head – Ozone free lamp – Higher efficiency – Less heat – Built in Active Power Control (APC™)

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Efficiency

Electrical Control

H-UV Lamp

Matching of Components

less energy, MORE Curepower

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Sounds magical…

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H-U Lamps (K-Supply ) • UV lamp manufacturing • Design • Manufacturing In house with equipment manufacturing unit

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Magic? – Science! Original H-UV represents most advance technology

STANDARD QUARTZ

Special metal halide „doping“ QUARTZ used for H-UV bulbs

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H-UV bulb

Special lamp with tuned output: => Reducing Energy requirement by 66%

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H-UV Power Consumption What for: Effect: Costs:

Lamp creating H-UV radiation High intensity H-UV output 16kW

What for: Effect: Costs:

Lamp control Keeping H-UV bulb and output stable 3kW

What for: Effect: Costs:

Water Cooling Cooling of lamp head and heat sink 4kW

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Lithrone GL40 – H-UV

GL 40 H-UV One lamp H-UV dryer in the delivery

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Line Current

42 A/~

Power

(actual)

27 kW

Power

(apparent)

29 kVA

Printing technology Focus Ink Only

Conventional

UV Offset

H-UV

Very good

Fair

Very good

Protection

Fair

Good

Good

High Gloss Special substrates

Poor

Very good

Very good

Poor

Very good

Very good

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Gloss Technology

Gloss Points

Oilbased print Varnish

approx. 60

Waterbased Coating

approx. 70

Primer + UV

approx. 80

UV inks & coating (inline)

approx. 90

H-UV inks & coating (inline)

up to 95

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Green Printing

Going green without worries • • • •

IPA free Print Min. power consumption Preserving the touch of paper Safe for immediate post press handling

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Thank you for your attention! Uli Sause – Baldwin Technology

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An Eco-friendly application taking process to new levels of efficiency.

Printology H-UV

Tony Carter www.komori.eu

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H-UV Sheet-fed sales 68 sheet-fed presses

2 2

2

1 2

4 2 7

27

2

3

1 2

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Market segments • H-UV is adaptable and flexible. Packaging Market

On demand Printing

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Added Value Market

• H-UV proving that it can benefit all types of print markets.

On demand market  Efficient production requirements.  High quality control, standards.  H-UV reduces material cost and increases available production time.

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Added value market • Special substrates – Creative papers, Cardboards, plastics ….

• • • • •

High quality image Very heavy ink coverage High quality varnish Creative Drip off Ambitious creative prints

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Packaging market • Huge reduction of energy consumption. • Easier image match with other prints processes. • Higher flexibility. • Easier treatment of heat sensitive substrates. • Higher Quality of Images. www.komori.eu

WHAT ARE THE REAL BENEFITS TO YOU.

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Improvements in productivity  Immediate back side printing (shorter total turnaround time)  Immediate drying, ready for finishing.  Prints on heat sensitive stocks  Reduction of ‘work in progress’ space.  Smaller press footprint.  Heavy ink coverage benefits. www.komori.eu

Overhaul Quality improvement! • No changes in gloss or colour after drying. • Quality of heavy images. • Quality of the printed dot • Reduction of marking risks • Improved quality due to powderless operation • Print on difficult paper (difficult to dry) : Muncken, Chromolux… • You can feel the paper! www.komori.eu

Benefits to the environment! • Reduction of paper waste • No powder pollution • No ozone emission (waste of energy) • No heat emission (waste of energy) • Reduced compared to UV or IR drying electrical consumption • Valuable factory space www.komori.eu

Production comparison

Komori LS 840P conventional vs

Komori GL 840 H-UV

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CUSTOMER PROFILE Commercial Printer Equipment:  LS 529 HC H-UV (2012) 2,2 shifts/ week on yearly base.  GL 540 HC H-UV (2012) 2,5 shifts/ week on yearly base.

 LS 840 P conv. (2009) 3 shifts/ week on yearly base.  K-STATION www.komori.eu

K-STATION DATA

Press

Good copies /year

Plate changes/year

LS529 plus coater HUV

19,350.000

4,830 plate changes

GL540 plus coater H-UV

24,100,000

5,520

LS840P Conventional

27,000,000

3,450

 Real data from real production.

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Description

Production details •

LS840P Conventional printing.

Only APC year 3,540

251 Hours

4 mins 15 secs

2,006 Hours

34 mins

973,500 sheets

275 sheets

2,307 Hours

11,700c/hour

Faults due to set off

125,000 sheets

125,000 shts

Maintenance/Year

655 hours

Make Ready/ Year 3,540 Waste sheets/Year M/R, colour, register Production/Year 27,000,000 sheets

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Data

Customer request! • H-UV Technology • More productive • Better quality • Less maintenance • Less paper consumption

• Less fault percentage • Diversification • Added value • Figures………….. Which configuration?

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GL 840P H-UV/ including A-APC- and PDC-SX Fact: • €185.000 euro more ink cost a year (H-UV)

Don’t panic yet!

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GL 840P H-UV figures: Plate change A-APC versus APC • 3540 plate changes a year:  APC: 251 hours  A-APC: 59 hours

= Savings 192 hours

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More productivity! H-UV Make ready versus conventional  Conventional make ready  3540 x 34 min.= 2,006 hours  H-UV make ready  3540 x *20 min.= 1,180 hours = Savings 826 hours

*Make ready time given by Nord imprim and DM Print (Both GL 840P HUV users).

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More savings…..of course! Maintenance H-UV vs conventional  Conventional given by K-station on yearly base: 655 hours  H-UV given by Nord Imp. and DB print: 351 hours = Savings 304 hours Maintenance includes: • Greasing • Cleaning (delivery etc ….) • Daily maintenance jobs by operators.

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Looks better already! •

Savings A-APC/H-UV make ready/ Maintenance:

• Total savings 1,324hours.

Finished yet?...... of course not!

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Waste sheets!  Conventional make ready sheets 973.500 sheets  Faults due ink set off 125.000 sheets Total: 1.098.500 sheets

 H-UV make ready sheets: 513.300 sheets (N.I&DB 145 sh) Savings: 582.200 sheets Is this the only savings related to paper? NOT AT ALL!!! www.komori.eu

(data K-station )

PDC-SX and HUV advantage • PDC-SX advantage – Read color bar in the middle of the sheet.

• Paper size 1 cm less in cumfrence! – H-UV advantage – No space needed for suction wheels!

• Paper size 2 cm less Lateral • What does that mean in figures or sheets? 856.000 sheets 68.000 kg. (calculated 115 grs.)

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What about speed! •

K-station data LS 840P conventional 11.739 s/h ( 2.307 hours) Normal for a Komori press

•

But H-UV can run faster! Average 12.750 s/h. 27 Mili. Sheets= 2.117 hours savings 190 hours.

Do you want me to continue?

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Summary of all savings

Plate change

LS840P

GL840P

251hrs

59 hrs Savings 192 hrs

Make-ready

2,006 hrs

1180 hrs Savings 826 hrs

Maintenance

655 hrs

350 hrs Saving 304 hrs

Wasted sheets

1,098,500

513,300 sheets Savings 582,200 sheets

Speed Advantage H-UV/PDC-SX

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11,700 sph- 2,037 hrs

12,750 s/hr 2,117 hrs

0

856,000 sheets 68,000kg

Savings 190 hrs

What is the end result?

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Facts! Producing the same as a conventional printer on his LS840P in a year: He needs:  1512 hours less (€378,000 )  1.438.000 sheets less (€68,000 ) TOTAL : €446,000 More cost ink: €180.000 266,000 per annum

BENEFIT €

What does that mean in real production figures?

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Today and tomorrow! •

Today-LS840P

•

Tomorrow-GL840P, AAPC, PDC-SX

•

Plate changes -3540

•

Plate changes-5740

•

Good copies -27 million

•

Good copies -33.5 million

CONVINCED? Well I am…….

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I REST MY CASE!

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KOMORI H-UV today!  H-UV is proven and can benefit your business.  Just listen to users in Europe to get an insight into its success.

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Questions?

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