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  • November 7, 2003

546 mm-cutoff 16-page web press

World's shortest changeover times achieved with combination of new technologies

[ Development Background ] [ Features ] [ Basic Specifications ]

Development Background
As harsh business conditions continue, printing companies are finding that the needs of their customers are also increasingly stringent. In other words, while printing companies are being exposed to price competition, customers are demanding the same or even better levels of quality. And in terms of being responsive to the increasing diversity of print jobs and maintaining customers, it is becoming necessary even for offset web presses to be capable of handling short run jobs.

One of Komori Corporation's R&D concepts is "Harmony of People, the Environment, and Machines," and printing companies in particular are being compelled by environmental laws and regulations, as well as by clients, to be environmentally responsive.

And so now Komori has developed System 35S, based on the following concepts:
. Uncompromising quality
. Relentless focus on productivity
. More support for small print runs
. Building presses that are good to work with and good for the environment

Komori has built up considerable research into sectional drive technology, preparing for the right time to release it to the market while putting itself in a good position to respond to customer needs. At the recent IGAS 2003, Komori exhibited the first System 35S press fitted with sectional drive, and has now decided to launch the system due to the overwhelming response.

Features of the System 35S
Komori has pioneered many achievements in the field of commercial offset web presses other than newspaper web presses. In addition to the highest levels of quality, this means Komori presses offer drastically reduced print make-ready times, and better support for achieving high productivity in short-run jobs.

With systems such as Full APC (fully automatic plate changer), KHS-AI (Komori KHS System AI fitted with a self-learning function for fast registration, fast color adjustments, and fast fold registration), and parallel control (more about this later), Komori has achieved the world's fastest single make-ready (taking less than 10 minutes for a make-ready that previously took 30 to 40 minutes). By combining these technologies with sectional drive, Komori can now offer the world's shortest job changeover times.

1. Employing sectional drive
Each unit and folder is equipped with its own independent drive motor. This enables unit-based adjustments for any discrepancies in cylinder phases. And as make-ready tasks can be performed at the same time, make-ready times can be further reduced.

2. World's fastest full APC (fully automatic plate changer)
Setting printing plates in a holder and pressing a button is all that it takes to have the used plates discharged and new plates mounted automatically. The world's fastest plate changes can be achieved-eight plates, 90 seconds.

3. Parallel control
During a conventional make-ready, tasks such as plate changing and blanket cleaning each take about 10 minutes and are performed one at a time. By performing these simultaneously in parallel, print make-ready times are dramatically reduced.

4. KHS-AI system with self-learning functions
- AI stands for Advanced Interface
With our conventional KOMORI KHS System, the ink film on the rollers is set in advance according to the image carried on the plate, and the ink spreads across the rollers so that color matching is made easy right from the start-up time. However, printing companies make fine adjustments based on their own quality standards as well as to satisfy those of their clients. And slight color changes occur depending on the printing materials and environmental factors such as temperature and humidity. The self-learning function automatically performs optimal color matching by merging these fine adjustments with the color changes. You can think of a machine equipped with KHS-AI as a machine that improves itself with this repetition of adjustments and optimization.

The Actual Effectiveness of Installing AI: The Case of Company A
The number of wasted sheets at start-up time (per job) was usually around 1,500 to 2,000 sheets without the Hyper System. Company A was able to report that the actual effectiveness of installing the KOMORI KHS System AI brought this down to as low as 200 sheets. Company A's data for the Hyper System without the self-learning function was around 800 sheets.

5. About the IGAS 2003 Demonstration
At IGAS 2003, System 35S was put to the challenge of a time trial in a demonstration based on an example of providing each of six stores with 4,000 B4 leaflets. The result? Printing was completed in 15 minutes. This means a reduction down to one-third of conventional systems, a speed that amazed many of the IGAS attendees.

Basic Specifications

Max. printing speed 800 rpm Basis weight 40 to 130 g/m2
Max. web diameter 1,100 mm Cut off 546 mm
Web width 625 to 880 mm Signatures B4: 2P, 4P, 8PB5: 8P, 16P

Web Offset Printing Department
Komori Corporation
Tel: 81-3-5608-7816

[ Development Background ] [ Features ] [ Basic Specifications ]

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