People & Print

Technical details
KBA Rapida 106 DriveTronic SPC

Clear & Concise is manufactured by Koenig & Bauer AG

which reserves the right to carry out

modifications without prior notice.
No part of this publication may be
reproduced in any way without the
Sheet format:
manufacturer‘s permission. Illustrations
Maximum (straight printing/perfecting) 740 x 1060 / 740 x 1060 mm may depict special features not included
Minimum (straight printing/perfecting) 340 x 480 / 400 x 480 mm in the basic press price.

Print format: For further information please

contact our sales department at:
Maximum 730 x 1050 mm
Koenig & Bauer AG
Maximum before perfecting 720 x 1050 mm Sheetfed offset presses
Postfach 020164,
Substrates1): 01439 Radebeul, Germany
Standard 0.06 - 0.7 mm Friedrich-List-Str. 47
01445 Radebeul, Germany
with lightweight equipment 0.04 mm
Tel: (+49) 0351 833-0
with board-handling equipment 1.2 mm Fax: (+49) 0351 833-1001
with corrugated equipment 1.6 mm Web: www.kba-print.com
Press with perfecting 0.8 mm E-mail: [email protected]
05/2008-e. Printed in Germany
Production speed2):
Up to 8 printing units 18,000 sheets/hr Our agency:

KBA RAPIDA 106

Press with perfecting in straight mode, 18,000 sheets/hr
up to 8 printing units
Press with perfecting in perfecting mode, 15,000 sheets/hr
up to 8 printing units

Pile height3):
Feeder
Delivery
1,300
1,200
mm
mm
DriveTronic SPC
Plate and blanket dimensions: Technical information
Plate size 795 x 1060 mm
Standard copy line 36 mm
Blanket size 860 x 1070 mm

1)
Printability is also influenced decisively by the flexural rigidity of the substrate
2)
Dependent on individual processing parameters, e.g. the inks and substrates used
3)
From floor / without non-stop operation
KBA Rapida 106 DriveTronic SPC Sheetfed offset The benchmark for productivity

Rapida 106 DriveTronic SPC

The benchmark for productivity

The revolution: DriveTronic SPC New functionalities and function

(= Simultaneous Plate Change) principles
DriveTronic SPC is the latest expression The full potential of DriveTronic SPC is
of KBA’s commitment to advanced dedi- demonstrated in combination with the
cated-drive technologies. With this new automation concept KBA-Tronic and
system, the plate cylinder is freed from an array of further concepts to reduce
all intermediate drive elements such as makeready times. Makeready savings of
gears and clutches. Whole mechanical up to 65 per cent are possible.
assemblies have been eliminated. This
speeds up the changeover processes
significantly, permitting appreciable

M any printers are in the meantime

producing for worldwide customers,
or otherwise exploiting the benefits of
DriveTronic dedicated drive
technology
The direct drive concept was already
reductions in makeready times.

globalisation with regard to materials introduced in 2000 with the shaftless

supplies, labour costs or investment and DriveTronic Feeder.
tax incentives. Those operating solely At drupa 2004, KBA again underlined its
on their domestic markets, on the other technology leadership with the presen-
hand, rely on the innovative strengths tation of DriveTronic Side Lay (SIS) and
of the printing press manufacturers DriveTronic Infeed, a sidelay-free infeed
to further the optimisation of their system and motorised adjustment for
production processes and in this way individual front lays.
to compensate the purported location
disadvantages.

KBA innovation drive

Innovations from across the whole KBA
product range are examined constantly
to identify integration potential for the
sheetfed offset process, keeping a con-
stant eye on the central goals of faster
makeready and even greater productiv-
ity. Automation options from the most
varied origins have been developed fur-
ther and adapted to the specific needs
of sheetfed offset users.

2 3
KBA Rapida 106 DriveTronic SPC Sheetfed offset DriveTronic

DriveTronic – Concept
Function principles
and their benefits

The drive concept Simultaneous plate change with DriveTronic Feeder

The development was still viewed DriveTronic SPC Four independent, electronically con-
with scepticism a few years ago, but The plate changing process now takes trolled drives for
intensive industrial trials have proved just one minute, irrespective of the
KBA’s sheetfed offset designers right: number of printing units. At the same • feeder head
Dedicated drives with liquid-cooled time, further valuable functions are • suction belt
high-torque motors now form the heart available to the operator: • pile transport for the main pile
of DriveTronic SPC. • pile transport for the auxiliary pile in
Successful interdisciplinary optimisation • Electronic setting of the start of print non-stop operation
has achieved previously unknown power • Electronically controlled circumferen-
densities. All parts which come into tial register eliminate wear-prone feeder compo-
contact with the cooling medium are • Plate changing parallel to other press nents such as clutches, cardan shafts
manufactured in stainless steel. processes and timing gears. Ultimate preset
capabilities provide for exceptionally
reduced makeready.

DriveTronic Infeed DriveTronic SideLay DriveTronic Plate Ident

All settings at the feed line are motor- (SIS = Sensoric Infeed System) Special register marks on the plates
ised. To further reduce makeready times, With DriveTronic Side Lay, a conven- are used to preset the registration for
the operator is offered clear, graphics- tional side lay is no longer necessary. all plate cylinders before printing even
based menu screens with access to: The sheet is pulled to its correct lateral begins. At the same time, DriveTronic
Comparison of plate changing costs Number of plate changes Costs alignment not on the feed table, but Plate Ident reads a data matrix code
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 • Gripper margin settings (positioning instead by way of an axially shifted copied onto the plates to ensure that
Basis: Rapida 106-6+L,
of the image relative to the front gripper bar on its way to the impres- each plate is assigned to the correct
press-hour rate € 350 0E

2500 E
edge of the sheet) sion cylinder. The positioning is defined unit on the press.
• Skew feed correction (e.g. to com- at the console and can be preselected
Plate change: 5000 E

7500 E
pensate inaccurately cut substrates) with the job changeover program. As
• Individual adjustment of the front the sheet no longer has to be pulled,
DriveTronic SPC - 1 minute 10000 E

12500 E
lays, should the leading edge of the more time is available for alignment at
sheet not be straight the feed line, which naturally promotes
Conventional press - 1 minute per unit 15000 E
• Front lay cover height adjustment to an excellent feed register. DriveTronic
6 units = 6 minutes Cost benefit with 17500 E
accommodate different substrate SideLay earned KBA the 2007 GATF
DriveTronic SPC: 20000 E
thicknesses InterTech Technology Award of the
After 1,000 plate changes, the cost approx. E 30,000 22500 E
Printing Industries of America/Graphic
benefit of the Rapida 106 with SPC 25000 E
Arts Technical Foundation (PIA/GATF).
amounts to 27500 E

30000 E
approx. € 30,000 32500 E
DriveTronic SPC 35000 E
Press without SPC technology

4 5
KBA Rapida 106 DriveTronic SPC Sheetfed offset Concepts to reduce makeready times

Concepts
to reduce makeready times
Function principles
and their benefits

Job changeover program Recalling of saved presetting data Optimised press start
The job changeover program has been All job-related data can be saved via It is possible to preselect a higher
specially developed to integrate seam- the ErgoTronic control console and can press speed when starting production
lessly into the operating philosophy of then be recalled at any later date in on the Rapida 106. Efficiency is further
the ErgoTronic control console. While case of repeat jobs. As a result, the enhanced by the two-stage impres-
current production continues, the press is ready for production even faster sion switching. First, the inking and Multiple-circuit washing system Washing times:
Fully automatic coater cleaning
operator can already load the next job and start-up wastage is reduced to a dampening units are dropped onto the This system comprises several independ- system Complete coating change:
and can preselect all the associated minimum. plate. Subsequently, the blanket cyl- ent washing circuits and spray systems. Dispersion to UV (or vice versa)
All components which come into
makeready processes. When the program inder is brought into contact with the Individually matched washing programs approx. 8 minutes
contact with the coating are cleaned
is subsequently activated, all the rel- predampened and inked plate. When the and solvents can be selected via the Simple coating change:
efficiently within the press. There is no
evant processes run fully automatically sheets arrive at the first printing unit, console to suit the ink system in use Dispersion to dispersion (or UV to UV)
need to remove components for external
and in their logical sequence. It is no the press accelerates to the preselected (hybrid/UV/conventional). Makeready is approx. 1-2 minutes
cleaning. All operator actions are per-
longer necessary to activate individual speed and the second stage of the also shortened with the multiple-circuit formed via the control console.
process steps and there are thus also no impression-on switching is triggered. washing system, especially on hybrid Washing programs of varying lengths
avoidable interruptions to negatively This provides for a better drag coef- presses. can be selected.
influence the overall makeready time. ficient on the sheet, fast attainment
of an ink-water balance and minimised
Preselection options: start-up waste.
• Plate changing processes
• Washing processes
• Format-related settings
• Substrate-related settings
• Sheet travel settings Comparison of coating supply Weeks Time in hours
cleaning 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52

Basis: Rapida 106-6+L, cleaning for 0

change “Dispersion to dispersion”, 5

1 cleaning cycle per shift, 3 shifts per 10

day, 5 days per week, 52 weeks 15

20

Cleaning time: 25

30

KBA system - 2 minutes 35

Saving with KBA system: 40

Alternative system - 5 minutes approx. 60% 45

50
After 52 weeks, the saving with the 55
KBA system amounts to 60

65
approx. 60% KBA system 70
Alternative system

6 7
Coating forme change Automatic suction ring positioning production on the press. This function is ErgoTronic ACR
The automated coating forme change (ASP) especially useful when perfecting with This system for automatic register cor-
function guarantees maximum conven- Automatic positioning of the suc- frequent format changes. rection comprises a camera installed
ience for the operator. All process steps tion rings on the delivery sheet brake at the control console, an integrated
are triggered at the key panel on the relieves the operator of otherwise time- computer and the corresponding soft-
coating tower itself and then run auto- consuming manual settings. It is only ware. It uses the camera to determine
matically. A pressure roller smoothes the necessary to specify the desired suction register differences and communicates
forme onto the cylinder as it is mounted ring positions at the ErgoTronic console; appropriate adjustment values to the
and thus eliminates all need for manual all further process steps run fully lateral, circumferential and diagonal
intervention. automatically. It is even possible to register systems on the individual
make corrections without interrupting printing units.

Makeready comparison, coating No. of coating forme changes Time in hours

Makeready comparison, suction rings No. of positioning processes Time in hours
forme change 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000
Basis: Rapida 106-10 SW5, press-hour
0 0
Basis: Rapida 106-6+L, press-hour rate rate € 400 5
€ 350 25 10
Suction ring positioning: 15
50 20
Coating forme change: 25
75 Fully automatic positioning of 3 suc- 30
KBA system, automated - 2 minutes tion rings (ASP) - 0 minutes Saving with ASP: 40
100 45
approx. 83 hours
Saving with KBA system: 50
Alternative system, manual - 125 Manual positioning of 3 suction rings 55
approx. 133 hours
6 minutes - 5 minutes 60
150 65
70
After 2,000 coating forme changes 175 After 1,000 settings of the suction 75
with the KBA system, the saving rings with ASP, the saving amounts 80
200 85
amounts to to 90
225 95

approx. 133 hours and KBA system, automated coating forme change approx. 83 hours and Fully automatic (ASP) 100

approx. € 46,666 approx. € 33,333

250
Alternative system, manual coating forme change Manual setting

8 9
KBA Rapida 106 DriveTronic SPC Sheetfed offset At a glance:

Rapida 106-8 SW4

At a glance:
A Recall saved data (1 minute) P Sheet travel optimisation (2 minutes)
without DriveTronic SPC:
A FAPC (7 minutes) P 2nd pull register/colour (3 minutes)
H Pile change (4 minutes)
Necessary makeready:
A Suction ring positioning (5 minutes) Complete job changeover: Plate
A Blanket washing (3 minutes) change, substrate change (format and

The full potential with DriveTronic SPC A

A
P
Impression cylinder washing (4 minutes)
Ink run up program (1 minute)
1st pull register/colour (3 minutes)
thickness)

Equipment features:
FAPC - Fully Automatic Plate Change,
multiple-circuit washing system,
The diagrams below compare the makeready times for the Rapida 106 in different configurations and with different DensiTronic professional, LogoTronic
levels of equipment. with CIP4 integration, recalling of
It is here assumed that a press crew always comprises a printer (P) and a helper (H). saved presetting data, job changeover
Automatic components are indicated with an A program, optimised press start,
suction ring positioning, register
Makeready processes which can run simultaneously
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Time in minutes
• Plate change - blanket washing • Plate change - impression cylinder washing
• Plate change – transfer of all presetting data • Roller washing – blanket washing

Rapida 106-6+L ALV2 P 1st pull register/colour (3 minutes)

Rapida 106-8 SW4
A Job changeover program (1 minute) A Blanket washing (4 minutes) A Job changeover program (1 minute)
without DriveTronic SPC: with DriveTronic SPC:
A Impression cylinder washing (4 min.) A Roller washing (4 minutes) A SPC (1 minute) P Sheet travel optimisation (2 minutes)
H Pile change (4 minutes) P 2nd pull register/colour (3 minutes)
A Suction ring positioning (ASP) (1 minute) P Coating forme change (2 minutes)
Necessary makeready: Necessary makeready:
H,P Ink duct cleaning (4 minutes) A Ink run up program (1 minute) A Blanket washing (3 minutes) Complete job changeover: Plate
Complete job changeover: Plate
H Pile change (4 minutes) P 1st pull register/colour (3 minutes) change, substrate change (format and A Suction ring positioning (ASP) (1 minute) change, substrate change (format and
A Fully automatic coating change (1-2 min.) P Sheet travel optimisation (2 minutes) thickness), coating forme change, A Recall saved data (1 minute) thickness)
A Recall saved data (1 minute) P 2nd pull register/colour (3 minutes) coating change (same system) and two A Impression cylinder washing (4 minutes)

A FAPC (3 minutes) ink changes A Ink run up program (1 minute) Equipment features:
DriveTronic SPC, multiple-circuit wash-
Equipment features: ing system, DensiTronic professional,
FAPC - Fully Automatic Plate Change, LogoTronic with CIP4 integration,
multiple-circuit washing system, recalling of saved presetting data, job
DensiTronic professional, LogoTronic changeover program, optimised press
with CIP4 integration, recalling of start, suction ring positioning, register
saved presetting data, job changeover
program, ink duct cleaning, fully au-
tomatic coating change, coating forme
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Time in minutes change, optimised press start, register 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Time in minutes

Rapida 106-6+L ALV2 Rapida 106-8 SW4

A Job changeover program (1 minute) A Roller washing (4 minutes) A Job changeover program (1 minute)
with DriveTronic SPC: with DriveTronic SPC:
A SPC (1 minute) A Impression cylinder washing (4 minutes) A SPC (1 minute)
A Blanket washing (4 minutes) P Coating forme change (2 minutes) A Blanket washing (4 minutes)
Necessary makeready: Necessary makeready:
H Pile change (4 minutes) A Ink run up program (1 minute) Complete job changeover: Plate A Suction ring positioning (ASP) (1 minute) Only section and plate change
H,P Ink duct cleaning (4 minutes) P 1st pull register/colour (3 minutes) change, substrate change (format and A Recall saved data (1 minute)
A Suction ring positioning (ASP) (1 min.) P Sheet travel optimisation (2 minutes) thickness), coating forme change, A Impression cylinder washing (4 minutes) Equipment features:
A Fully automatic coating change (1-2 min.) P 2nd pull register/colour (3 minutes) coating change (same system) and two P 1st pull register/colour (3 minutes) DriveTronic SPC, multiple-circuit wash-
A Recall saved data (1 minute) ink changes ing system, DensiTronic professional,
LogoTronic with CIP4 integration,
Equipment features: recalling of saved presetting data, job
DriveTronic SPC, multiple-circuit wash- changeover program, optimised press
ing system, DensiTronic professional, start, register
LogoTronic with CIP4 integration,
recalling of saved presetting data, job
changeover program, ink duct clean-
ing, fully automatic coating change, 10 11
coating forme change, optimised press
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Time in minutes start, register 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Time in minutes
KBA Rapida 106 DriveTronic SPC Sheetfed offset Facts and figures

The maximum annual production out-

put of the Rapida 106 is calculated by Production output per year with SPC
multiplying the number of jobs by the Production output per year without SPC
average run length.

DriveTronic SPC –
The Rapida 106 without SPC achieves
an annual output of 35,631,000
sheets.

The Rapida 106 with SPC achieves an

a profitable investment annual output of 41,970,000 sheets.

This represents a plus for the

Rapida 106 with SPC of
35,631

Facts and figures 6,339,000 sheets. 41,970

30 32 34 36 38 40 42 Millions of
sheets

The basis for determination of the payback period is a work-centre and profitability calculation for the printing press.

The following basic data are assumed for the calculations: The payback period is influenced deci-
sively by the planned revenue.
Press: Rapida 106-8 with perfecting (4/4) Payback period with SPC (same revenue as without SPC)

Manning: 1 printer and 1 helper If it is assumed that the owner of

Payback period without SPC
Working days: 250 the Rapida 106 does not pass on the Payback period with SPC (cost benefit passed on to customer)
Shifts per day: 3 benefits of faster makeready to the
Working hours per shift: 7.4 hours customers, then this results in a
Capacity utilisation: 300% payback period for the press as a
Availability: 85% whole of
Makeready per job: with DriveTronic SPC 16 minutes
34
without DriveTronic SPC 27 minutes 34 months.
Maximum printing speed: 15,000 sheets/hour in perfecting mode,
18,000 sheets/hour in straight printing If the press owner passes on the cost 43
Average run length: 10,000 benefits, then the payback period is
Printing passes: 1 practically the same as for a press
without SPC. 45
Revenue = Production costs + overheads + 10%

(Social conditions and working hours in accordance with German guidelines)

10 20 30 40 50 60 Months

Taking into account the different

makeready times per job, calculation Print jobs per year with SPC
of the maximum production capacity
for the Rapida 106 produces the fol-
Print jobs per year without SPC Applying the basic assumptions defined at the beginning for the profitability calculation,
lowing results: the payback period for the automation module DriveTronic SPC is shown to amount
to approximately ten months.
The Rapida 106 without SPC is able to
handle 3,563 jobs.

The Rapida 106 with SPC is able to

handle 4,197 jobs.

This represents a plus for the Rapida 3,563

106 with SPC of

634 jobs. 4,197

12 13

3,000 3,200 3,400 3,600 3,800 4,000 4,200 Number

of jobs
KBA Rapida 106 DriveTronic SPC Sheetfed offset KBA Complete

Breaking the speed limit...

Components for faster makeready
KBA Complete

• AllJobpreselected
changeover program •Multiple-circuit
Multiple-circuit washing system • Automated coating forme change • Ink run-up program •System
ErgoTronic ACR •Reel-to-sheet
RS 105
Well advised makeready processes
run fully automatically upon activation different solvents
washing system for component for automatic de-
termination of lateral, circumferential integration
feeder with console

• Suction ring positioning (ASP)

Remote-controlled positioning of the
• Optimised press start
Press runs up to production speed with
and diagonal register corrections

•dataRecalling of saved presetting •FullyCoating supply system

automatic cleaning system for
suction rings on the delivery sheet
brake
two-stage impression-on

the coater

JDF-integrated networking on the KBA stand at drupa 2008

T he newly founded independent com-

pany KBA Complete offers consulting
services for the print industry. On the
realised worldwide together with MIS
developer Hiflex. Many other technology
and service partners also contribute to
play important roles. The JDF format
provides for improved interface com-
munication with all system components
KBA LogoTronic professional
•Combined
DensiTronic professional
density and colour measur-
•Optical
Automatic Plate Punch (APP)
plate positioning, with punch-
•100%QualiTronic professional
inspection with inline density
•- Fully
Perfecting
automatic conversion
•FullyFAPC
automatic plate changing system
•Simultaneous
DriveTronic SPC
plate changing in all
ing system with dynamic ink zone ing according to the position of the measurement and control, also for with console integration (without SPC) printing units, with electronic adjust-
basis of individual solutions tailored solutions, enabling KBA Complete to act involved. Comprehensive benchmarking, image installation both before and after a
regulation ment of the start of print, electroni-
to the specific demands of printing as a one-stop supplier. finally, enables a figure to be placed perfecting unit cally controlled circumferential regis-
businesses, the objective is to enhance on the results of the optimised work
•- Fast-reacting
Single-train inking unit •FourDriveTronic Feeder ter and parallel washing processes
productivity, for example through process KBA Complete analyses workflows and processes.
• DensiTronic PDF •- Extended
Delivery independent, electronically con-
optimisation and the use of an MIS. uncovers optimisation potential as the
- Scanning of the printed sheet delivery 1,400, 2,400 •- Chamber
Coating tower - Disengaged when not in use trolled drives, providing for ultimate
Ever more urgent demands are today
basis for unique strategies tailored to
the company concerned. The manage-
The target is to reduce operating costs
while at the same time improving
and comparison with the PDF from
prepress
or 3,800 mm
- Importing of presetting data
blade system with
anilox roller
- Oscillation timing adjustment
with console integration
preset capabilities •Presetting
DriveTronic Plate Ident
of registration for all plate
placed on the work processes in print ment information system (MIS) and im- productivity, which in turn leads to - Setting values can be saved - All register settings as console
- All functions of DensiTronic - Low maintenance cylinders before start of printing,
companies. Reasons are to be seen,
on the one hand, in the rising cost
plementation of the JDF standard here enhanced profitability and competitive-
ness. In addition, KBA Complete offers
professional - Air-cushion sheet guiding functions (axial/radial/diagonal) •Remote
DriveTronic Infeed
motorised adjustment of the
checking of the correct assignment of
plates to the individual printing units
pressures, but also in the customers’ concepts for new products and new
•- With
Dampening unit feed line and individual front lays by way of a data matrix code
growing expectations with regard to
extended networking and the integra-
business models in the print industry,
together with the requested support •Management
LogoTronic professional
system for KBA presses
•- IRVariDry high-performance dryers
and hot-air dryers
•- Fast
Coating supply system
makeready through automatic
function to remove hickeys
- Importing of presetting values
tion of downstream finishing processes.
In all such situations, KBA Complete is
during implementation. A particular
focus is placed on future-oriented
(PressWatch, SpeedWatch)
- JDF/JMF interface for an unbroken
- 3 UV modules cleaning of all components which
come into contact with the coating
•Sidelay-free
DriveTronic SIS
lateral alignment
a competent partner with corresponding technologies and approaches, such as - No need for further manual cleaning
workflow
know-how. Complex network projects are web-to-print, e-business or RFID, as
well as on solutions to develop business
- Central colour database
- Links to report data from
•- Inline
QualiTronic
inspection system
with climate-neutral printing. - Quality control for each individual
DensiTronic, DensiTronic PDF,
QualiTronic sheet
- Pallet dockets - Inspection on the last impression
cylinders before and after
perfecting (optional)