9_Komori-1

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Komori H-UV

An Eco-friendly application taking

process to new levels of efficiency

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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

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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.

Process Technology People

Press room efficiency

…

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

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Why we developed H-UV.

 Compete with digital

 High cost of materials.

 Printing on difficult

substrates.

 Print On demand

requirements.

 A constant battle to

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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

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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.

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The Future!

• Speed up the

manufacturing process. • Reduce production cost. • Broaden your market

possibilities.

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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.

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H-UV printing

 Reduced initial cost

 Low Heat generation

 Ozone free production

 Environmentally friendly

 Carton board printing

possible

 Plastic printing possiblel

Black

Magenta

Yellow

One H-UV lamp

Cyan

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

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H-UV benefits

 A real alternative to

conventional printing.

 An application that

increases your product

quality, productivity

and truly benefits your

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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

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Resins

Oils _{Dry ink film} Resins Oils Penetration Evaporation Conventional drying

Drying mechanism

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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

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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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UV

dry ink film

oligomers monomers photoinitiator

UV curing

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Spectrum mercury UV – H-UV lamp Wave length [nm] 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100. 0 200 260 320 380 440

Inks and varnishes must be adjusted to the lamp spectrum !

Heat formation Ozone formation Surface curing UV varnishes Depth curing Adhesion Pigmented inks Depth curing Adhesion Opaque white

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Is H-UV able to improve conventional and UV offset printing? - Drying - Carbonating - Need of varnishing - Other benefits ? - Areas of usage ?

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Drying / Curing differences

Standard UV ink H-UV ink

 No spray powder needed !

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conventional Non UV ink

Standard UV ink

Carbonating differences coated paper

H-UV ink

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

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oilbased

Print quality on uncoated offset paper

H-UV

=> More contrast => Brighter colours => Bigger gammut

=> Less ink consumption

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Possible applications / Benefits of H-UV inks Packaging Commercial 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

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NewV set KHS (high sensitive)

Uncoated, Coated papers / boards

Available ink series for H-UV

NewV poly KHS (high sensitive)

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Consumables Conventional HUV

Ink EUR/kg 8.00 15.00

Dispersion varnish EUR/kg 1.50

-Varnish H-UV EUR/kg - 16.00

Spray powder EUR/kg 7.00

-Energy cost EUR/kWh 0.14 0.14

Replacement HUV bulb EUR/piece 600.00

Consumables consumption Conventional HUV

Ink kg/year 1'800.00 1'620.00

Dispersion varnish kg/year 5'500.00

-Varnish H-UV kg/year - 0.00

Spray powder kg/year 360.00

-Energy kW/h 58.00 20.00

Energy consumption per year 189'312.00 65'280.00

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Working times Conventional HUV

Daily working time (2 shift) in h 13.60 13.60

Working days per year 240.00 240.00

=> h per year 3'264.00 3'264.00

Cost per working hour 290.00 290.00

Annual cost calculation Conventional HUV

Inks 14'400.00 24'300.00

Dispersion varnish 8'250.00

-Varnish H-UV - 0.00

Spray powder 2'520.00

-Energy 26'503.68 10'053.12

Replacement H-UV bulbs - 2'611.20

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H-UV Drying

• Printing & Drying

– Drying technology

• H-UV Technology

– Power Consumption

– Efficiency

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PRINTING & DRYING

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Best technology available

(Application vs. technology)

conventional

Sealer /

Coating

Ink only

UV Offset

High Gloss

Coating

Special

Substrates

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Drying principles / options

79kW

1 day >90kW

No Dryer IR & HA Dryer UV Dryer EOP + 1

Absorption Evaporation Curing

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Where does H-UV fit?

H-UV

conventional

Sealer /

Coating

Ink only

UV Offset

High Gloss

Coating

Special

Substrates

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

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DRYER - TECHNOLOGY

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Example: 5Colour + Coater

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IR/HA Power Consumption

What for: IR lamps boosting temperature of paper and water Effect: evaporation of water born materials

Costs: 52kW

What for: Hot Air for boosting ambient temperature in press Effect: Creating environment to absorb water vapour

Costs: 18kW

What for: Exhaust enabling Air exchange

Effect: Removing hot, damp air to keep process going

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Example: 5Colour + Coater

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UV Power Consumption

What for: UV lamp creating radiation

Effect: broad exposure of radiation to the sheet

Costs: 71kW

What for: Exhaust to atmosphere

Effect: Removing ozone contaminated air to atmosphere

Costs: 7kW

What for: Water Cooling

Effect: Cooling of dryer parts in press to protect from overheating

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Example: 5Colour + Coater

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H-UV TECHNOLOGY

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Radiation

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H-UV Dryer

H-UV lamp head

– Ozone free lamp

– Higher efficiency

– Less heat

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Efficiency

less energy, MORE Curepower

Matching of Components

H-UV Lamp

Electrical Control

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H-U Lamps

(K-Supply )

• UV lamp manufacturing

• Design

• Manufacturing

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Magic? – Science!

STANDARD

QUARTZ

used for H-UV bulbs

Special metal halide „doping“

Original H-UV

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H-UV bulb

Special lamp with tuned output:

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H-UV

Power Consumption

What for: Lamp creating H-UV radiation Effect: High intensity H-UV output

Costs: 16kW

What for: Lamp control

Effect: Keeping H-UV bulb and output stable

Costs: 3kW

What for: Water Cooling

Effect: Cooling of lamp head and heat sink

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Lithrone GL40 – H-UV

One lamp H-UV dryer in the delivery

GL 40 H-UV

Line Current 42 A/~ Power (actual) 27 kW

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Printing technology

Focus Conventional UV Offset H-UV

Ink Only Very good Fair Very good

Protection Fair Good Good

High Gloss 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

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Thank you for your attention!

Uli Sause – Baldwin Technology

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Printology

H-UV

An Eco-friendly application taking process to

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

2

8

2

4

7

2

1

2

3

2

1

2

27

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Market segments

Packaging Market Added Value Market On demand Printing

• H-UV is adaptable and flexible.

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

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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

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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.

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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

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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!

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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

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Production comparison

Komori LS 840P conventional

vs

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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

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K-STATION DATA  Real data from real

production.

Press Good copies /year Plate changes/year LS529 plus coater H-UV 19,350.000 4,830 plate changes GL540 plus coater H-UV 24,100,000 5,520 LS840P Conventional 27,000,000 3,450

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Production details

• LS840P Conventional printing.

Description Data

Only APC year 3,540

251 Hours 4 mins 15 secs Make Ready/ Year

3,540 2,006 Hours 34 mins Waste sheets/Year M/R, colour, register 973,500 sheets 275 sheets Production/Year 27,000,000 sheets 2,307 Hours 11,700c/hour

Faults due to set off 125,000 sheets 125,000 shts

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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)

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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

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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

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Looks better already!

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

• Total savings

1,324hours.

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Waste sheets!

 Conventional make ready sheets 973.500 sheets (data K-station )

 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

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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

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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.

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LS840P GL840P Plate change 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 11,700 sph- 2,037 hrs

12,750 s/hr 2,117 hrs

Savings 190 hrs

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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

BENEFIT €266,000 per annum What does that mean in real

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Today and tomorrow!

• Today-LS840P

• Plate changes -3540 • Good copies -27 million

• Tomorrow-GL840P, AAPC, PDC-SX

• Plate changes-5740

• Good copies -33.5 million

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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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