Heidelberg Perfecting Technology: Technical Innovations Combine to Maximize Quality and Productivity
Reliable and stable production is a prerequisite for speed and
flexibility, in particular with short to medium runs involving
frequent job changes, but ensuring smooth sheet travel for a wide
range of printing stock - from lightweight paper and card-
board to plastics - represents a huge challenge for perfecting technology.
There are three factors that give presses with a perfecting device the advantage of much higher productivity than for straight printing but with virtually the same high print quality:
The main tasks of the perfecting device are to reverse the sheet already printed on one side as quickly and precisely as possible, avoiding any damage to it and without disrupting the sheet flow. The basic principle predominantly found with presses arranged in rows - gripping the rear edge of the sheet - is the same with most manufacturers. For the past 30 years, however, Heidelberg has been different, adopting the principle (patented until 2003) of pincer grippers which it developed itself. These grippers are used in both straight and perfecting printing and deliver con-
sistently smooth sheet travel. This minimizes the effect of acceleration forces on the sheet, which is always kept at virtually the same tension and transferred with maximum precision. The result is exceptional register accuracy.
A further key factor for the productivity of Heidelberg perfecting presses - which are currently capable of producing up to 15,000 sheets an hour - is the true-to-register three-drum perfecting device developed by Heidelberg, which has the potential to handle a much larger sheet throughput. It con-
sists of a transfer drum, a storage drum and a reversing drum. The unique selling points of this Heidelberg unit are the storage drum with its eccentric rotary suckers and the reduced-diameter reversing drum which also uses the pincer gripper system mentioned above, ensuring a high level of register accuracy at any speed.
Three-drum perfecting - "streamline" sheet travel, even for thick printing stock
The successful three-drum perfecting principle has been further improved on the new Speedmaster CD 74 with perfecting device by incorporating a restyled double-sized transfer cylinder directly in front of the storage drum. The cylinder takes the sheet from the last straight-mode impression cylinder. The transfer system's drum shells can be folded up or extended. In per-
fecting mode, they are extended for thicker printing stock in order to ensure optimal sheet transfer at all times to the storage drum, which is also twice the standard size.
board to plastics - represents a huge challenge for perfecting technology.
There are three factors that give presses with a perfecting device the advantage of much higher productivity than for straight printing but with virtually the same high print quality:
- reliable sheet transfer with high register accuracy,
- innovative, ink-repellent cylinder jackets and
- a high level of automation.
The main tasks of the perfecting device are to reverse the sheet already printed on one side as quickly and precisely as possible, avoiding any damage to it and without disrupting the sheet flow. The basic principle predominantly found with presses arranged in rows - gripping the rear edge of the sheet - is the same with most manufacturers. For the past 30 years, however, Heidelberg has been different, adopting the principle (patented until 2003) of pincer grippers which it developed itself. These grippers are used in both straight and perfecting printing and deliver con-
sistently smooth sheet travel. This minimizes the effect of acceleration forces on the sheet, which is always kept at virtually the same tension and transferred with maximum precision. The result is exceptional register accuracy.
A further key factor for the productivity of Heidelberg perfecting presses - which are currently capable of producing up to 15,000 sheets an hour - is the true-to-register three-drum perfecting device developed by Heidelberg, which has the potential to handle a much larger sheet throughput. It con-
sists of a transfer drum, a storage drum and a reversing drum. The unique selling points of this Heidelberg unit are the storage drum with its eccentric rotary suckers and the reduced-diameter reversing drum which also uses the pincer gripper system mentioned above, ensuring a high level of register accuracy at any speed.
Three-drum perfecting - "streamline" sheet travel, even for thick printing stock
The successful three-drum perfecting principle has been further improved on the new Speedmaster CD 74 with perfecting device by incorporating a restyled double-sized transfer cylinder directly in front of the storage drum. The cylinder takes the sheet from the last straight-mode impression cylinder. The transfer system's drum shells can be folded up or extended. In per-
fecting mode, they are extended for thicker printing stock in order to ensure optimal sheet transfer at all times to the storage drum, which is also twice the standard size.
The storage drum has a rotary sucker system that tensions and
aligns the sheet perfectly, ensuring optimal registration. The
intake ports integrated into the shells of the stor-
age drum are a further new feature. They apply uniform suction to the sheet over its entire length, even with thick printing stock, and prevent waves from forming. This means that the sheet is held securely on the storage drum right from its front edge - a key factor for the high register accuracy of the Heidelberg perfecting technology.
The storage drum is followed by an eccentrically shaped single-sized reversing drum with a pincer gripper pad rail which routes the sheet in a gripper closure to the downstream printing unit.
In straight printing applications, perfecting presses from Heidelberg deliver the same print quality and productivity as presses without a perfecting device. The Prinect CP2000 Center press control system can be used to switch perfecting presses to straight printing.
Top quality thanks to ink-repellent transfer surfaces
The properties of cylinder surfaces are decisive for the print quality and productivity of a press. If ink is smeared on the transfer cylinders, this im-
pairs the quality of the recto side, increases the amount of cleaning required and means that the surface is less durable. Consequently, Heidelberg perfecting technology features innovative exchangeable cylinder jackets with special ink-repellent coatings. These jackets - 'TransferJacket Plus' (for transport/transfer cylinders) and 'PerfectJacket Plus' (on the post-reversal impression cylinders) - ensure that the sheet which is not yet dry passes through the perfecting printing units with virtually no ink/quality losses.
age drum are a further new feature. They apply uniform suction to the sheet over its entire length, even with thick printing stock, and prevent waves from forming. This means that the sheet is held securely on the storage drum right from its front edge - a key factor for the high register accuracy of the Heidelberg perfecting technology.
The storage drum is followed by an eccentrically shaped single-sized reversing drum with a pincer gripper pad rail which routes the sheet in a gripper closure to the downstream printing unit.
In straight printing applications, perfecting presses from Heidelberg deliver the same print quality and productivity as presses without a perfecting device. The Prinect CP2000 Center press control system can be used to switch perfecting presses to straight printing.
Top quality thanks to ink-repellent transfer surfaces
The properties of cylinder surfaces are decisive for the print quality and productivity of a press. If ink is smeared on the transfer cylinders, this im-
pairs the quality of the recto side, increases the amount of cleaning required and means that the surface is less durable. Consequently, Heidelberg perfecting technology features innovative exchangeable cylinder jackets with special ink-repellent coatings. These jackets - 'TransferJacket Plus' (for transport/transfer cylinders) and 'PerfectJacket Plus' (on the post-reversal impression cylinders) - ensure that the sheet which is not yet dry passes through the perfecting printing units with virtually no ink/quality losses.
The secret of the TransferJacket Plus jackets lies in their
extremely ink-repellent surfaces. These were developed using
nanotechnology and satisfy two key requirements. They deliver
virtually uniform high quality on both sides of the sheet and
significantly improve press productivity thanks to much shorter
washing times than with conventional coatings. During field tests
in 2004, users achieved time savings of up to 80 percent.
Perfecting presses can now also be used with a wider range of
printing materials and support higher production speeds.
The PerfectJacket Plus ceramic jackets developed by Heidelberg deliver high quality and smooth sheet travel. The jackets have an exceptionally ink-repellent surface with a very fine structure and are also easy to exchange. The jackets themselves are made from high-quality steel followed by a layer of titanium and, finally, the silicon coating. They are used across the various Heidelberg formats. According to Heiko Mazur, Managing Director of Häuser KG in Cologne [see 'Perfecting flexibility'], "Compared to the coatings previ-
ously used, we now obtain much better quality with perfecting printing, in particular with contones and solids. Shorter washup times result in a big improvement in press capacity utilization thanks to quicker job changes - a factor that makes a significant contribution to the higher productivity of the new press."
Heidelberg is the first manufacturer to also offer jackets for retrofitting.
Last but not least, patented Venturi sheet guide plates in the delivery guide the printed sheet very gently and without scratching on a cushion of com-
pressed air to the delivery pile. The sheets are deposited in the delivery using optimized gripper bars.
Conclusion
Thanks to the intelligent interplay of fundamental technical innovations - from sheet transfer and drum coating to largely contact-free sheet transport to the delivery - Heidelberg perfecting technology means top quality and maximum productivity.
Perfecting flexibility
The example of Häuser KG in Cologne shows how perfecting technology from Heidelberg can be used to increase productivity. Häuser KG is one of the few print media businesses in Germany to have a business model focused on Internet-based job acquisition. A new Speedmaster CD 74 eight-color press with perfecting device acquired in November 2005 has signif-
icantly increased flexibility, providing key support for the further expansion of the 30-strong family company.
In order to make the most of the Internet, of course, jobs have to be pro-
cessed much more quickly. "Production times of four hours from receipt of an order to the finished product are no problem for us," states Heiko Mazur, Managing Director of Häuser KG. The production setup has to be just as quick and flexible.
The new Heidelberg Speedmaster CD 74-8 plays an important role in this. This is particularly true for Internet orders, almost 95 percent of which are four-color jobs. "As regards color and quality, these jobs can be handled extremely well with an eight-color press. The high level of automation offered by the Speedmaster CD 74 allows us to cut setup times signifi-
cantly. In perfecting mode there are no longer any limits on speed, quality and printing stock thickness - the potential additional throughput is over 40 percent compared to a straight press. And with a view to the imminent increase in orders, the press still has sufficient capacity to cope with double the throughput," explains Mazur.
Image 1:
Three drums for speed and register accuracy - the perfecting system on the Speedmaster CD 74 optimizes sheet travel, even with heavy grammages.
Image 2:
The surface of the new TransferJacket Plus from Heidelberg is highly ink-repellent.
The PerfectJacket Plus ceramic jackets developed by Heidelberg deliver high quality and smooth sheet travel. The jackets have an exceptionally ink-repellent surface with a very fine structure and are also easy to exchange. The jackets themselves are made from high-quality steel followed by a layer of titanium and, finally, the silicon coating. They are used across the various Heidelberg formats. According to Heiko Mazur, Managing Director of Häuser KG in Cologne [see 'Perfecting flexibility'], "Compared to the coatings previ-
ously used, we now obtain much better quality with perfecting printing, in particular with contones and solids. Shorter washup times result in a big improvement in press capacity utilization thanks to quicker job changes - a factor that makes a significant contribution to the higher productivity of the new press."
Heidelberg is the first manufacturer to also offer jackets for retrofitting.
Last but not least, patented Venturi sheet guide plates in the delivery guide the printed sheet very gently and without scratching on a cushion of com-
pressed air to the delivery pile. The sheets are deposited in the delivery using optimized gripper bars.
Conclusion
Thanks to the intelligent interplay of fundamental technical innovations - from sheet transfer and drum coating to largely contact-free sheet transport to the delivery - Heidelberg perfecting technology means top quality and maximum productivity.
Perfecting flexibility
The example of Häuser KG in Cologne shows how perfecting technology from Heidelberg can be used to increase productivity. Häuser KG is one of the few print media businesses in Germany to have a business model focused on Internet-based job acquisition. A new Speedmaster CD 74 eight-color press with perfecting device acquired in November 2005 has signif-
icantly increased flexibility, providing key support for the further expansion of the 30-strong family company.
In order to make the most of the Internet, of course, jobs have to be pro-
cessed much more quickly. "Production times of four hours from receipt of an order to the finished product are no problem for us," states Heiko Mazur, Managing Director of Häuser KG. The production setup has to be just as quick and flexible.
The new Heidelberg Speedmaster CD 74-8 plays an important role in this. This is particularly true for Internet orders, almost 95 percent of which are four-color jobs. "As regards color and quality, these jobs can be handled extremely well with an eight-color press. The high level of automation offered by the Speedmaster CD 74 allows us to cut setup times signifi-
cantly. In perfecting mode there are no longer any limits on speed, quality and printing stock thickness - the potential additional throughput is over 40 percent compared to a straight press. And with a view to the imminent increase in orders, the press still has sufficient capacity to cope with double the throughput," explains Mazur.
Image 1:
Three drums for speed and register accuracy - the perfecting system on the Speedmaster CD 74 optimizes sheet travel, even with heavy grammages.
Image 2:
The surface of the new TransferJacket Plus from Heidelberg is highly ink-repellent.
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The Benefits of Heidelberg Perfecting Technology at a Glance
- 4/4, 5/5 and 6/6-color print products are created with high
levels of productivity
- Printing stock thickness of 0.03 - 0.8 millimeter at up to
15,000 sheets an hour
- High print quality thanks to PerfectJacket Plus and
TransferJacket Plus techno-
logy
- Easy jacket changing produces consistent quality
- Precise registration
- Rapid job changes between thick and thin printing materials
- High level of automation allows shorter setup times
- Automated changeover between straight-printing and
perfecting modes
