"Star Peripherals from Heidelberg" Article Series, Part I
Smaller, More Powerful, More Efficient - the New AirStar 3000
Air Supply System from Heidelberg
The Heidelberger Druckmaschinen AG (Heidelberg) Star System covers the whole system solution with peripherals for Speedmaster presses. The key peripherals are connected to the press via the Prinect CP2000 Center control station by means of CANopen data bus.
All peripherals are developed directly by Heidelberg or in close cooperation with leading suppliers. This provides a whole raft of benefits for customers, including extensive automation functions, standardized and easy-to-follow navigation and one-stop installation and maintenance.
Heidelberg has recently unveiled a new generation of peripherals featuring the AirStar 3000 air supply cabinet, CombiStar 3000 combination unit and DryStar 3000 LYL and DryStar 3000 UV dryers. These enable printers to increase productivity by up to 30 percent.
This is reason enough to cover these innovations for peripherals in a series of articles. In the first part, we will look at air supply.
The Heidelberger Druckmaschinen AG (Heidelberg) Star System covers the whole system solution with peripherals for Speedmaster presses. The key peripherals are connected to the press via the Prinect CP2000 Center control station by means of CANopen data bus.
All peripherals are developed directly by Heidelberg or in close cooperation with leading suppliers. This provides a whole raft of benefits for customers, including extensive automation functions, standardized and easy-to-follow navigation and one-stop installation and maintenance.
Heidelberg has recently unveiled a new generation of peripherals featuring the AirStar 3000 air supply cabinet, CombiStar 3000 combination unit and DryStar 3000 LYL and DryStar 3000 UV dryers. These enable printers to increase productivity by up to 30 percent.
This is reason enough to cover these innovations for peripherals in a series of articles. In the first part, we will look at air supply.
AirStar 3000 - up to 50 percent less power consumption, 45
percent less heat transfer and a 50 percent smaller footprint
Every press needs air, for example to separate the sheets in the feeder, to transport the sheets between the printing units and to ensure optimum pile stacking in the delivery. While many press manufacturers "hide" the blowers required for this underneath the press, Heidelberg has long been committed to the concept of a decentralized, high-performance and easy-to-access air supply cabinet. Since 1995, Heidelberg has installed over 15,000 of these cabinets on Speedmaster presses. The new AirStar 3000 air supply system takes this success story one stage further with a quantum leap in terms of energy efficiency and new blower technology. The AirStar 3000 features two new types of air generator: a two-stage claw pump and - for the first time in the print media industry - a turbo radial blower with very high efficiency of 70 percent.
In future therefore, all Speedmaster XL 105 presses will be equipped with the AirStar 3000 air supply cabinet as standard and, as of fall this year, this will also be the case for most other Speedmaster models. This innovative technology delivers annual electricity cost savings of up to 8,000 Euro based on a Speedmaster XL 105-6+LX in three-shift operation.
Every press needs air, for example to separate the sheets in the feeder, to transport the sheets between the printing units and to ensure optimum pile stacking in the delivery. While many press manufacturers "hide" the blowers required for this underneath the press, Heidelberg has long been committed to the concept of a decentralized, high-performance and easy-to-access air supply cabinet. Since 1995, Heidelberg has installed over 15,000 of these cabinets on Speedmaster presses. The new AirStar 3000 air supply system takes this success story one stage further with a quantum leap in terms of energy efficiency and new blower technology. The AirStar 3000 features two new types of air generator: a two-stage claw pump and - for the first time in the print media industry - a turbo radial blower with very high efficiency of 70 percent.
In future therefore, all Speedmaster XL 105 presses will be equipped with the AirStar 3000 air supply cabinet as standard and, as of fall this year, this will also be the case for most other Speedmaster models. This innovative technology delivers annual electricity cost savings of up to 8,000 Euro based on a Speedmaster XL 105-6+LX in three-shift operation.
Groundbreaking technology from Heidelberg
"Presses and peripherals today need to be closely coordinated with one another," explains Ruben Schmitt, Head of the "Air Systems" development department at Heidelberg. "The high production speed of a Speedmaster XL 105 requires optimum sheet travel. The press regulates this very conveniently by adapting the air quantities automatically to the printing stock and production speed. This automatic regulation and the ability to store all air settings along with the print job have necessitated a whole new concept. An "one-size-fits-all" air supply system or installing a central air generation system for the whole print shop is no longer sufficient," Schmitt adds.
The key objective of the development is to ensure optimum availability of the press. The individual air consumers such as the blowing devices in the printing units or on the transfer drums are therefore not supplied directly from the blowers. Instead, a central air distribution tube is installed along the press which supplies almost all the press's blast-air consumers. This tube is fed from several identical blowers belonging to the AirStar 3000 system. If one of these blowers fails, another one automatically cuts in, thereby significantly minimizing the risk of a press standstill.
"Presses and peripherals today need to be closely coordinated with one another," explains Ruben Schmitt, Head of the "Air Systems" development department at Heidelberg. "The high production speed of a Speedmaster XL 105 requires optimum sheet travel. The press regulates this very conveniently by adapting the air quantities automatically to the printing stock and production speed. This automatic regulation and the ability to store all air settings along with the print job have necessitated a whole new concept. An "one-size-fits-all" air supply system or installing a central air generation system for the whole print shop is no longer sufficient," Schmitt adds.
The key objective of the development is to ensure optimum availability of the press. The individual air consumers such as the blowing devices in the printing units or on the transfer drums are therefore not supplied directly from the blowers. Instead, a central air distribution tube is installed along the press which supplies almost all the press's blast-air consumers. This tube is fed from several identical blowers belonging to the AirStar 3000 system. If one of these blowers fails, another one automatically cuts in, thereby significantly minimizing the risk of a press standstill.
Innovative turbo radial blowers
Heidelberg uses completely new blower technology based on turbo radial blowers in the AirStar 3000. These high-tech blowers run at speeds of up to 15,000 revolutions per minute - a speed unimaginable just a few years ago.
The advantages of this for the printshop are clear. With an efficiency factor of 70 percent (as opposed to 30-35 percent with conventional air supply cabinets for presses from other manufacturers), the system converts the electrical energy it uses highly efficiently. This reduces power consumption by up to 50 percent. The high efficiency also reduces heat transfer to the pressroom by up to 45 percent.
Through the use of new materials, the developers at Heidelberg have succeeded in designing extremely low-wear, almost maintenance-free blowers. The contact-free compression means there is hardly any running noise. This is another major advantage for day-to-day print shop operations.
All turbo radial blowers have a dynamic speed regulator. This ensures that the speed of the blowers always corresponds exactly to the press's current air requirements. This solution saves energy and, ultimately, cash for the customer, as frequently only 30-50 percent of the actual blower capacity is required in practice. Only when processing very thick grammages or running the press at high speed, when powerful suction and blast air support is required for sheet travel, is the blower speed increased.
In addition to the turbo radial blowers, the AirStar 3000 also uses a newly developed two-stage claw pump that can form two pressure levels at each stage. This system enables four different pressure levels to be generated - and does so using only a single drive. As a result, the dimensions can be kept small, and this is reflected in the significantly reduced footprint of the AirStar 3000.
Heidelberg uses completely new blower technology based on turbo radial blowers in the AirStar 3000. These high-tech blowers run at speeds of up to 15,000 revolutions per minute - a speed unimaginable just a few years ago.
The advantages of this for the printshop are clear. With an efficiency factor of 70 percent (as opposed to 30-35 percent with conventional air supply cabinets for presses from other manufacturers), the system converts the electrical energy it uses highly efficiently. This reduces power consumption by up to 50 percent. The high efficiency also reduces heat transfer to the pressroom by up to 45 percent.
Through the use of new materials, the developers at Heidelberg have succeeded in designing extremely low-wear, almost maintenance-free blowers. The contact-free compression means there is hardly any running noise. This is another major advantage for day-to-day print shop operations.
All turbo radial blowers have a dynamic speed regulator. This ensures that the speed of the blowers always corresponds exactly to the press's current air requirements. This solution saves energy and, ultimately, cash for the customer, as frequently only 30-50 percent of the actual blower capacity is required in practice. Only when processing very thick grammages or running the press at high speed, when powerful suction and blast air support is required for sheet travel, is the blower speed increased.
In addition to the turbo radial blowers, the AirStar 3000 also uses a newly developed two-stage claw pump that can form two pressure levels at each stage. This system enables four different pressure levels to be generated - and does so using only a single drive. As a result, the dimensions can be kept small, and this is reflected in the significantly reduced footprint of the AirStar 3000.
Total success in practice
With the tried-and-tested AirStar 2000, Heidelberg was already ahead of the game in the field of air supply technology. Most of the rival systems are twice as big, consume much more energy (this can quickly add up to an extra 10,000 Euro a year compared with the AirStar 2000) and generate more waste heat. With the AirStar 3000, Heidelberg is widening its lead in the air supply sector. Energy consumption and footprint have been reduced by up to 50 percent compared to its predecessor, and heat transfer to the press has been reduced by up to 45 percent. This lowers operating costs and facilitates the print process.
Hannes Manz, Production Manager at AZ-Druck und Datentechnik in Kempten, is impressed by Star peripherals: "With the best peripherals, you tend to forget after a couple of months where they actually are in the print shop. The AirStar 3000 is one of these. It works flawlessly and reliably, and adjusting the air settings using the Prinect CP2000 Center is easy and saves a lot of time. Our electricity bill has dropped dramatically since we installed it - I never would have believed that peripherals could have such an effect on energy costs."
Reliable scroll compressors
In addition to the AirStar 3000, every Speedmaster XL 105 is also equipped with a ScrollStar compressor. This generates the highly compressed air used for supplying all pneumatic cylinders in the press, including the new InkLine 3000 ink supply system. For compressed-air generation too, Heidelberg uses different technology from its competitors. The scroll compressor works on a contact-free basis, making it very quiet and low-maintenance. It does not need any oil for lubrication. This eliminates the usual high maintenance outlay and ultimately reduces press standstills.
To be continued...
Image 1: Star System from Heidelberg
The Heidelberg Star System covers the whole system solution with peripherals for Speedmaster presses. These are connected to the press via the Prinect CP2000 Center control station by means of CANopen data bus.
Image 2: Control cabinet
AirStar 3000 is the new air supply cabinet for blast and suction air generation.
Image 3: Claw pump
The innovative two-stage claw pump combines the pressure and vacuum stages.
Image 4: Turbo radial blowers
In the AirStar 3000, a turbo radial blower with very high efficiency of 70 percent is used for the first time in the printing industry. It reduces energy consumption by up to 50 percent. It also cuts heat transfer to the pressroom by up to 45 percent.
Image 5: Efficiency graphic
Efficiency comparison of turbo radial blowers and side channel blowers.
With the tried-and-tested AirStar 2000, Heidelberg was already ahead of the game in the field of air supply technology. Most of the rival systems are twice as big, consume much more energy (this can quickly add up to an extra 10,000 Euro a year compared with the AirStar 2000) and generate more waste heat. With the AirStar 3000, Heidelberg is widening its lead in the air supply sector. Energy consumption and footprint have been reduced by up to 50 percent compared to its predecessor, and heat transfer to the press has been reduced by up to 45 percent. This lowers operating costs and facilitates the print process.
Hannes Manz, Production Manager at AZ-Druck und Datentechnik in Kempten, is impressed by Star peripherals: "With the best peripherals, you tend to forget after a couple of months where they actually are in the print shop. The AirStar 3000 is one of these. It works flawlessly and reliably, and adjusting the air settings using the Prinect CP2000 Center is easy and saves a lot of time. Our electricity bill has dropped dramatically since we installed it - I never would have believed that peripherals could have such an effect on energy costs."
Reliable scroll compressors
In addition to the AirStar 3000, every Speedmaster XL 105 is also equipped with a ScrollStar compressor. This generates the highly compressed air used for supplying all pneumatic cylinders in the press, including the new InkLine 3000 ink supply system. For compressed-air generation too, Heidelberg uses different technology from its competitors. The scroll compressor works on a contact-free basis, making it very quiet and low-maintenance. It does not need any oil for lubrication. This eliminates the usual high maintenance outlay and ultimately reduces press standstills.
To be continued...
Image 1: Star System from Heidelberg
The Heidelberg Star System covers the whole system solution with peripherals for Speedmaster presses. These are connected to the press via the Prinect CP2000 Center control station by means of CANopen data bus.
Image 2: Control cabinet
AirStar 3000 is the new air supply cabinet for blast and suction air generation.
Image 3: Claw pump
The innovative two-stage claw pump combines the pressure and vacuum stages.
Image 4: Turbo radial blowers
In the AirStar 3000, a turbo radial blower with very high efficiency of 70 percent is used for the first time in the printing industry. It reduces energy consumption by up to 50 percent. It also cuts heat transfer to the pressroom by up to 45 percent.
Image 5: Efficiency graphic
Efficiency comparison of turbo radial blowers and side channel blowers.
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