Economic efficiency in 4-over-4- or 5-over-5 printing

The new Rapida 105 establishes itself as a long perfecting press

(PresseBox) ( Würzburg, )
The medium-format Rapida 105 was unveiled by KBA in November 2011. This new sheetfed offset press has significant differences to pre-vious generations. The Rapida 105 is based on the same technological platform as the high-tech Rapida 106, that with a maximum output of up to 20,000sph and its makeready times defines the benchmarks in medi-um format. Its intelligent automation concept, various configurations and optional features available combined with a maximum production speed of 16,000sph (17,000sph with the HS speed enhancement package), the internationally successful Rapida 105 targets printers with limited in-vestment budgets. Since Drupa 2012, the new press has been available and sold as a long perfecting press for 4-back-4 and 5-back-5 printing. Its sheet travel systems and maximum sheet format makes its superior to presses from other well-known manufacturers, who still print with single-size impression cylinders without washing units.

The Rapida 105 perfecting press also features double-size impression cylinders and transfer systems as standard. Sheet travel has become even more streamlined thanks to the substructures and printing units taken from the Rapida 106. The quick-reacting inking units with a single-train ink feed and large rollers for less waste are identical to those found in the Rapida 106. The console’s preset capability, smooth running and contact-free sheet transfer supported by Venturi air-cushioned sheet guides, a feature not found in many comparable presses. This predes-tines the new Rapida 105 for perfecting, even when using heavy sub-strates. Its universal grippers accommodate any changes in substrates without adjustments. All registers can of course be remotely adjusted at the ErgoTronic console or automatically checked and corrected with ErgoTronic ACR.

Perfecting with Rapida 106 technology inside

The three-drum perfecting system in the Rapida 105 which ensures an output of up to 14,000sph in perfecting mode, is the same as in the Rap-ida 106, that has a maximum output of up to 18,000sph. There are op-portunities to increase the Rapida 105’s output in future. Precise perfect-ing register is achieved with a broad range of substrates. The fully-automatic conversion between straight and perfecting mode and vice versa only takes two minutes. The Venturi system also prevents the substrate from coming into contact with certain press components before the printing zone. Mechanical guides are only needed when printing with carton board.

Jackets on the impression cylinders after perfecting ensure invariable quality on both sides of the sheet. The drum shells feature an anti-marking coat and twisting suckers spread the rear edge of the sheet tight on the storage drum when perfecting. Sheet travel below the perfecting drum and in the delivery can be observed via a video system allowing the air-stream to be adjusted precisely. All settings for sheet travel from the feeder to the delivery can be saved and recalled for repeat jobs.

Intelligent automation boosts efficiency

Long Rapida 105 perfecting presses with optional automated plate changers score points when it comes to the time saved during job changes. In just five and half minutes, including the necessary register zeroing, all plates are changed in eight or ten printing units.

KBA CleanTronic ensures fast washing with job-specific preset pro-grams. Dry cloths and ready-impregnated cloth rolls are used instead of commonplace, high-maintenance brushes. Collection tanks or feedback systems for used washing materials are not necessary in the Rapida 105. One roll of cloth lasts up to 200 washing cycles. KBA CleanTronic is easy to operate and up to three minutes faster than conventional brushing systems. Parallel washing programs cut job changeover times. Along with a swivelling washing bar for combined blanket and impression cylinder washing, also available is a multiple-media washing system (CleanTronic Multi) for different ink use and a safety function to eliminate waiting times before the cylinder is washed when printing with UV inks. Additionally, the “print clean” function removes the remaining ink from plates and blankets, thus slashing the time need for washing and the use of resources.

The Rapida 105 user can choose between the various KBA VariDry dry-ing systems (IR/hot-air, UV, HR UV) depending on the job mix. En-hanced energy efficiency and sustainability are shifted into the spotlight with the VariDryBLUE option. Dryer control is always dependant on the pile temperature. The individual drying modules and also the lamps can be changed or replaced between all positions without the need for tools.

In the delivery the Venturi sheet guiding system ensures an air-cushioned travel to the sheet filing at high speeds for even the most sensitive of substrates. The suction roller with presuckers and adjustable speed decelerate the sheets and facilitates precise pile formation. The amount of powder metered depends on output and format.

Preset capability virtually throughout

The console is a further highlight of the new Rapida 105. The touchscreen supports ergonomic access to all press functions and the menu is logically structured and easy to understand. The preset capabil-ity controlled via the ErgoTronic console, a feature found in all Rapidas, coordinates the whole makeready process in every press model. The large wall screen for visualisation of all press settings is another of its many new features. The JobAccess job changeover program coordi-nates various makeready processes at the push of a button. A remote maintenance module and a KBA LogoTronic production management system are all integrated into the console as well as optional measuring systems, such as ErgoTronic ColorControl (density and Lab measure-ments) or ErgoTronic ICR (register control).

Proven technology with enhancements

Despite the many technological features taken from the high-end Rapida 106, the new Rapida 105 perfecting press distinguishes itself greatly from its predecessors. Not only has the proven basic construction been enhanced by a new feeder and delivery and include some other tech-nical and visual improvements. The new Rapida 105 is a cutting-edge sheetfed offset press in every way.
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