KBA COMPACTA408/418/618/818

People & Print

Powerful Double-Circumference Presses for High-Volume Commercials

Competitive AdvantageMarket Opportunities

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Highlights

he KBA Compacta 408, 418, 618 and818 double-circumference commercial

presses are specifically engineered to printhigh-volume runs and high-paginationproducts. Low production costs perthousand copies give you that vital edgein a fiercely competitive market.

With the continuing boom in promotionalliterature and new magazine titles,commercial web offset will remain oneof the dominant production processeswithin the graphic arts industry.However, the quality, productivity,flexibility and economic efficiency ofcommercial presses must keep pace withincreasingly sophisticated customerexpectations.

KBA’s double-circumference presses –long-grain and short-grain presses forproducts from 32 to 80 pages – help you

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expand your position in the commercialarena by offering a logical, effectivechoice of automation and optionalmodules to enhance net output, handlingand production flexibility.

They let you configure your press to suityour market, whether you are lookingfor specialised equipment for printingbooks, or the flexibility to handle avariety of magazine formats and pagecounts.

Highlights at a glance

• KBA DriveTronic shaftless drives throughout

• Minimised lock-up slots to cut paper consumption and enhance format flexibility

• Automated plate changing• Optimised film inking units for precise,

uniform inking• Multi-ring bearings for a superb print

quality• High-performance KBA Pastomat RC

beltless reelstand with integrated KBAPatras M (manual) or KBA Patras A (automated) paper-logistics system

• antilevered turner bars and formers foreasy access

• Automatically convertible P5 folder for all the most widespread types of product

• Variable-format V5 gripper folder for short- and long-grain products

• Cutters for maximum productivity• Distributed, intelligent controls at

subassembly level• Console for convenient operation• JDF-based process integration via KBA

LogoTronic

or commercial printing, whatever the application, a KBA Compacta is

sure to be the right choice. Because ourpresses are purpose-designed in closecollaboration with you, our customers,and benefit from the most extensivepool of experience in press manufacturingcombined with the most advanced engineering and production processescurrently available.

As with any investment, careful planningis the key to success. Here at KBAexhaustive feasibility studies are followedby detailed project planning and schedul-ing. Our universally acknowledged high-precision engineering, supported bycutting-edge CNC processing stations,guarantees a superlative manufacturingquality and a long service life.

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Aggregates are pre-installed to cutassembly and commissioning times.A low level of maintenance, minimumdown times – even in triple-shift oper-ation – and a global service network ofqualified staff ensure a high, calculablelevel of press utilisation.

Intensive research and developmentactivities, with special emphasis onautomation and control, reduce yourmanning costs and improve your pro-duction performance.

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Investment

Precision EngineeringInvestment Planning

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Paper Logistics

K BA’s integrated paper-logistics system embraces total automation

of the paper flow, from reel receptionand storage to on-demand supply of theprepared reels to the reelstand, loadingonto the reelstand arms, and removaland disposal of the empty cores.Remote control and monitoring of theindividual sequences from cutting-edgeconsoles is a key feature.

The KBA PATRAS paper transport systemis module-based to offer a wide range ofversions, from manual to fully auto-matic, so that it can be custom-configured to suit individual productionspecifications and the space available.

The modular design of the reel logisticssystem, which is available in a choice ofautomation levels from manual to allautomatic, supports customisation tosuit specific production parameters andarchitecture.

KBA Patras is engineered for a longservice life and low maintenance, and isa real value-for-money investment.Optimising paper logistics with Patrasbrings substantial savings in costs andpaper waste.

The KBA Pastomat RC high-performancereelstand with central drive and dividedarms can be integrated easily into an

Just-in-TimePaper Logistics

High-performance KBA Pastomat RC reelstandfor web speeds of up to 15.2mps (2,992fpm)

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automated paper-logistics system.A new web is automatically spliced ontothe expiring web at full productionspeed. The absence of a belt drive onthe Pastomat RC makes splice pre-paration much easier.

The divided arms on the Pastomat RCare infinitely adjustable by push-button. The ability to handle reels ofdifferent widths affords a high level offlexibility in processing a variety of pro-ducts.

Separate brochures are available onstreamlining paper logistics with KBAPatras and on the new-generation KBAPastomat RC reelstand. The reels are driven via the core by robust AC motors

he printing couples in Compacta double-circumference presses are the

product of traditional, quality-focusedengineering skills combined with break-through technology. They are designedfor high-volume print runs in triple-shiftoperation. The cylinders for the printingplate and blanket promote a smoothmachine run and superb commercialprint quality even at the maximum web speed of 15 m/s (2,953 f/m).

Rigid side-frames made of solid cast iron,and the box-type design of the printingunits, prevent vibration even at maximumspeeds – an absolute essential for a high-grade print quality and the basis for manyyears of low-maintenance, error-freeoperation in the harsh routine of multi-shift production.

Whether you are aiming to print high-volume runs or short runs of high-pagination copies, KBA double-circumference presses will bring you big bottom-line benefits.

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The printing units in Compacta double-circumference presses combine innovative technology with proven features

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KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Printing Units

High-Quality Prints Focus on Printing Couples

High-quality production and smooth running even at maximum speed

T he film inking units on KBA double-circumference presses raise the bar

in precision inking. Specially designedrollers put ink to plate with absoluteprecision and uniformity. The ink is splitrepeatedly to create a fine ink film whichtransfers delicate lines and problematicalimages onto the paper with equal clarity.

The oscillation of the four speciallycoated ink drums provides for an exactdistribution of ink. The ink drums andduct rollers are connected to an ink-temperature control system and guaranteea uniform ink temperature for an optimumprint quality. The circulation systems forthe cooling water are controlledseparately.

Three forme rollers, one of them recipro-cating, transfer the ink uniformly to theplate and reliably prevent ghosting. The speed of the motor-driven duct rollercan be regulated from the console andfrom the ColorTronic desk. The inkingand dampening duct rollers have freelystorable acceleration curves so thatthey run up to colour faster.

The high-capacity ink ducts have cross-heads for torsional rigidity, a preciselydefined throw-on position and can beconnected to a central ink supply. Theink knives are segmented into zones andcan be preset and remotely adjustedfrom the ColorTronic desk. A digital linkto obtain presetting values from pre-pressis possible, in order to minimise make-ready times and wastage.

Film inking unit for a superb print quality

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KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Printing Units

Dampening unit for alcohol-free printing

Ink on the DotInking and Dampening Units

Low-alcohol dampening units enhancepress ecology and economy. The elec-trically driven rubber-coated duct roller,the chrome roller for dampening transferand the large-diameter reciprocatingplate dampener create a rapid ink/waterbalance during press start-up. The platedampener, like the ink forme rollers,follows the plate cylinder during cockingand is thrown on and off pneumaticallyduring job changes. The dampeningtrough is insulated, the level of the fountsolution is monitored electronically.

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Printing Units

T he KBA double-circumference presses are designed for maximum producti-

vity. Plate-changing has been automatedto cut makeready and down times. Thecircumference of the plate and blanketcylinders – and thus paper consumption –has been reduced by minimising the lock-up slot, which brings the added benefitof enhancing print quality by eliminatingvibration at high press speeds.

The plate cylinder and solid steel blanketcylinder are both nickel-plated, dynami-cally balanced and run in maintenance-free triple-ring bearings with zero play.Broad bearer rings made of special steelensure a smooth machine run and in-crease the service life of the press. Theblanket is tensioned evenly via two

spindles. Motorised adjustment of thesidelay, circumferential and diagonalregister from the console cuts set-uptimes and waste. The individual drivesassume the function of the unit-to-unitregister.

1 Ink duct2 Duct roller3 Film roller4 Ink distributor roller5 Ink drum6 Forme roller7 Reciprocating forme roller8 Dampening duct9 Dampening duct roller

10 Dampening transfer roller11 Plate dampener12 Plate cylinder13 Blanket cylinder14 Web

Output Up – Consumption DownPrinting Couples in Detail

12 13Automated Plate ChangeThe leading edge of the plate is

T he design of the turner-bar super-structure influences the versatility

and economic efficiency of the entirepress line. This is why KBA installs rapidturner-bar superstructures whose highperformance has already been proven ingravure printing. The turner bars arecantilevered to allow free access to thesuperstructure and rapid webbing-up.

Once in the superstructure, the web canbe slit into ribbons of different widths.Parallel turner bars position the ribbonsone above the other and guide them tothe former for the first length fold. Webinfeed has been optimised, the registerassembly and easy-access former can beshifted sideways or in the direction ofweb run.

The latest further developments serve toreduce air consumption and thus savevaluable energy. At the same time, theturner bars are contamination-free andpromote smoother ribbon travel. Linear-register rollers permit optimum adjust-ment of the cut-off register.

Slitters guarantee a precise scissor cut New turner bar materials for a stable web run

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The electrically controlled dedicateddrives for the draw rollers maintain auniform web tension. They can bepreset and adjusted by remote controlfrom the console, which dramaticallyshortens setting and makeready times.

Cooling rollers cool the web to ambienttemperature prior to infeed into thesuperstructure. The first cooling rollerdoubles as a measuring roller for webtension. The principle applied in KBA’schill roll stand, with its extreme angleof wrap, requires just a small volume ofwater to cool the web, which also cutsenergy consumption.

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Superstructure

High-Speed VersatilityFlexibility in the Superstructure

Each of the slitters has an adapter for adust extractor and can be adjusted remotelyfrom the console. The cutting pressurebetween the upper and lower knife isprecisely defined to produce a cleanscissor-cut with minimal abrasion.

Colour measurement and control for perfect printresults

Optimum efficiency at the chill roller stand

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses P5 Folder

T he output level and versatility of a web offset press are determined by

the folder. KBA double-circumferencepresses incorporate a KBA P5 folder

with five-part cylinders to accommodatehigh web speeds.

The heavy-duty folder has a modulardesign to allow you, the user, to specifythe configuration best suited to youroperations and your market.

The standard version offers a choice offirst cross fold and quarterfold in collectand non-collect mode. A double quarter-fold and overhead copy guidance into thedelivery of the lower quarterfold are alsostandard features, as are length and crossperforation. Options include a separatedelivery for crossfold production, asecond parallel cross fold and a sectionstitcher.

Whatever the level of sophistication youchoose, you will find that the convenienceand speed of automated press presettingand conversion from the console will

support a wide variety of products byhelping to minimise makereadies andchangeovers. With the P5 you can keepabreast of market trends by offeringyour clients new, attractive products.

The folder is also fully integrated intothe innovative shaftless drive system.There are no gears or clutches, and pressparts not scheduled for the next job canbe automatically disengaged duringchangeover. This reduces wear, tear and maintenance while boosting pressproductivity. The circumferential settingof the spider wheel can be adjusted onthe run to accommodate different copythicknesses and so ensure a problem-freedelivery. The position of the spider wheelcan be preset automatically during pro-duction changeovers.

A host of other features, such as a crossperforator with on-the-fly depth adjust-

More Productive TimeFast Pin Folder

An intelligent superstructure design supports folder versatility

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ment or three-stage product decelerationin the delivery, ease the press crew’s workload and enhance folder productivityand reliability.

A severer prevents damage to folderparts in the event of a paper jam. Thestop in the quarterfold can be cleanedof paper trimmings during the pro-duction run.

The P5 folder combines productionflexibility, rapid conversion, accuratefolding and low maintenance withextreme reliability and easy handling.

1 Former2 Forming rollers3 Driven draw roller4 Length perforation5 Cross perforation6 Driven draw roller7 Cutting cylinder8 Distributed drive9 Stitcher

10 Collecting cylinder11 Folding-jaw/folding-blade cylinder12 Folding-jaw cylinder13 Quarterfold blade14 Folding rollers15 Spider wheel16 Sheet delivery17 Cross-fold spider wheel18 Cross-fold delivery

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses V5 Gripper Folder

Upping Your OptionsFormat-Variable Gripper Folder

W eb offset printers, whose flexibilityis often limited by the fixed

format of their presses, will welcomeour V5 gripper folder’s ability to processboth short- and long-grain products.

Our expertise in gravure technology,especially in folder engineering, has en-abled us to create a folder for commercialpresses as well. A folder which, for thefirst time, makes it possible to switch aKBA Compacta 618, for example, from48 A4 pages long-grain to 60 (slightlyreduced) A4 pages short-grain. This fur-nishes much greater production flexibility.The V5 is the ideal solution to increa-singly fierce competition in the 32- to80-page market.

In order to make the most of this ver-satility you need a superstructure capable

of handling a large number of ribbons.Cut-off cylinders at the infeed to the V5folder allow the cut-off length to bevaried, just as in gravure, eg to 620 or413.3mm. It goes without saying thatthe V5 incorporates all the familiartechnical features of the P5 folder and,of course, individual drives.

The V5 broadens your options for maxi-mising plant utilisation and thereforeenhances press economy. It enables youto raise your competitive profile byoffering an extensive range of productsand react more flexibly to changes inmarket and customer demands.

And the V5 gives you a lot of otherbenefits including more room formanoeuvre in a fiercely competitivemarketplace. In some cases it can even

Cut-off cylinders at folder infeed support a wide choice of cut-off lengths

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save you the expense of investing in asecond press for short-grain products. If your job structure exploits the V5folder’s full potential, this can bringadditional, substantial, bottom-linebenefits.

A tailored superstructure concept is prerequisite to utilise the full variability of the V5

Dieses Konstruktionsprinzip senkt einer-seits Investitions- und Produktionskostendrastisch, bringt andererseits eine enormeProduktionsleistung. Der Abschnittapparatstellt die ideale Ergänzung zum KBA-Akzidenz-Falzapparate-Programm dar.Er optimiert die Produktion von 4, 8, 12 und 16 Seiten durch den Einsatz modern-ster Technologie und Fertigungsverfahren.

T he KBA cutter dramatically lowers investment and production costs.

The moving parts in the KBA cutter allrotate, so there is no braking effectcaused by deflection, and the press canrun at the optimum speed for the job.This is a big advantage – particularlywhen printing low-pagination copies –and substantially reduces costs whileenhancing output.

The cutter is the ideal complement toKBA’s range of commercial folders. Itsadvanced technology and engineeringoptimise the production of 4, 8, 12 and 16 pages.

Cutter technology trims also investment and production costs...

also as a complement to a standard folder

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KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Cutter

Trimming Production CostsSimple Cutter Handling

The essential details:

• Cut to 1/3 or 1/4 circumference• Two infeed formers, movable sideways

and with the web run• Variable infeed width• Variable length trimming opposite the

former nose• Splitting units in the spider wheels

The cutter permits optimised handling of low-pagination products

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses OPERA

All important commands are initiated from theuser-oriented control console

KBA OPERADialogue between man and machine

n the high-performance Compacta 215,the user-oriented control console

KBA ErgoTronic, the automatic press-presetting system KBA EasyTronic, theautomatic web tension control systemKBA WebTronic and the productionmanagement system KBA LogoTronic are important elements of an integratedautomation concept. Through thenetworking of intelligent control technologies at unit level, theoperating crew maintains full controlover the whole press throughout allphases of production. With KBA OPERA(Open Ergonomic Automation System),KBA furnishes the modules which areindispensable to master today's increasingly complex press installationsand the instant dialogue between manand machine which these demand.

KBA ERGOTRONICThe new control console of the Compacta215 is a perfect symbiosis of functionalityand aesthetic design. All important production commands, including thosefor automatic conversion of the folder,are initiated from the console. Clearlyarranged data screens with plain-textdisplays promote accurate and rapidhandling via touchscreen controls.

Remote diagnostics and maintenanceKBA service staff can be contacted atany time via a 24-hour hotline for promptand effective assistance. Modem facilitiesalso enable the KBA customer servicedepartment to communicate directly withthe computer systems of the Compacta215, ensuring that any malfunctionscan be located and rectified with anabsolute minimum of delay.

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Intelligent automation concepts relieve the press crew

KBA COLORTRONICThe ColorTronic desk is the press operator'scentral workplace and permits optimumhandling of the ink settings for the upperand lower printing couples. A presettingsystem for the ink keys is part of thestandard package. Broad LED strips provide an immediate indication of the

ink profiles set and facilitate fastcorrections when necessary.

KBA CIPLinkThe CIP3 converter CIPLink is an optionalcomponent of the KBA LogoTronic systemfor calculation of the area coverage, andthus of the ink key openings, on thebasis of pre-press data. The CIP3 filescan be imported from floppy disk, fromCD-ROM or online via a local network.In this way, the relevant data from pre-press can be transferred directlyinto the press in digital form.

KBA EASYTRONICThe automatic press presetting systemKBA EasyTronic raises the availability ofthe press and contributes to considerablesavings in wastage. It features, for example, automated web-threading,automatic web width conversion when

setting up a new job, run-out washing inaccordance with production demands,and defined pre-inking. All superstructure and folder componentsare preset on the basis of the pre-pressdata. A single press of a button providesfor optimised starting, setting-up andstopping of the press, ensuring theshortest possible production times and an absolute minimum of wastage.

KBA WEBTRONICThe self-regulating web tension controlsystem KBA WebTronic assists the operatorwhen starting up the press, takes careof web tension regulation during production, and thus contributesessentially to greater stability at allphases of the print run. This not onlyreduces the risk of web breaks at start-up, but also boosts net productionoutput and promotes uniformly highprint quality.

The goal for practically every print enterprise is to possess an unbroken

workflow from order receipt to productdispatch. Since so many differentmachines and programs are involved tocater for different product ranges, suchworkflows are scarcely available "off-the-shelf". Individual configurationsmust be tailor-made. This is also generally not a domain for "one-stop suppliers". KBA makes a dedicated contribution to networking and workflow with its management systemsLogotronic professional and Logotronicbasic, but at the same time workstogether closely with recognised suppliers of branch management soft-ware. The universal JDF format (JobDefinition Format) developed by the CIP4consortium, of which KBA is a member,permits data exchange with both

management information and prepresssystems. The JDF specificationtakes into account all process-relevantmodules. Data transfer, however, cannevertheless use the previously installedinterfaces.

Logotronic basicAll KBA Compacta presses are equippedas standard with the Logotronic basicversion of the system. This versionserves to transfer essential preset datato the press. Logotronic basic embracesthe optional modules CIPLink (CIP3/CIP4data transfer for press presetting) andlogging for paper and ink data. Theexisting company hardware (server) isused to implement the networking system.Presetting data for the ink keys and forthe duct roller settings are transferred.

Logotronic professionalTo support a digital exchange of job andpresetting data for the press, to permitimmediate monitoring and systematicevaluation of production data, and toestablish links to upstream PPS systemsor company EDP networks, the consolecan be further expanded by adding theopen production management systemLogotronic professional. The logging ofpress and production data facilitatesoperations management, with KBA Logotronic as a source of trulymeaningful statistics. Logotronic professional is the central element ofcommunication between KBA presses andthe corresponding print company MIS,whether via direct database access orvia JDF. The communication moduleJDFLink implements JDF dataexchange.

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KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Workflow

Important information on current print productioncan be called up from any location

• Improved cost accounting on the basis of exact press and production data (no daily worksheets to be completed by hand)

• Clearer overview through facility to retrieve all job, presetting and press data

• Comprehensive and transparent information for management

PressWatchThe Logotronic component PressWatchprovides management with an overviewof all the jobs currently being run.Counter states, printing speeds, job dataand progress, press status messages and a whole array of other relevantinformation can be displayed in realtime.

SpeedWatchSpeedWatch creates a time/speed diagram, similarly in real time, withwhich all events and messages for aselected press can be depicted.Correspondingly authorised persons areable to access this information via theInternet or the company Intranet.

JDFLink with Logotronic professionalInterconnection of Logotronic professionalvia the universal interface JDFLinkoffers the following advantages:

• Unbroken automated workflow (job data can be passed directly from the branch)

• Access to Logotronic professional fromall connected workstations

• Presetting and repeat data provide forshorter makeready times

• More effective production per shift• Less waste• Single data input brings greater

efficiency and reduces the risk of errors

KBA LOGOTRONICDigital workflow

Die Synchronisation der Antriebe erfolgt über dieelektronische Welle

Einzelantriebstechnik auch im Überbau

The drives are synchronised via an electronic shaft

Dedicated drives also in the substructure

oenig & Bauer’s new-generation double-circumference presses feature

KBA DriveTronic dedicated shaftless drivesinstead of a mechanical main shaft. Theposition-controlled and in part water-cooled AC servo motors are synchronisedvia a ‘virtual shaft’.

Individual drives for all subassemblies,from the infeed unit and printing couplesthrough to the chill roll stand, the drawelements in the superstructure and thevarious folder modules, cut wear and tearand provide for less maintenance, fastmakeready, high register precision andvibration-free running. The result is adramatic improvement in print quality.

Mechanical unit-to-unit registration isno longer necessary, as this function isassumed by the individual drives. Extramodules, eg an additional printing couple,can be added and the superstructure orfolder can be extended even years afterthe press originally came on stream. Infact, the shaftless drive technology per-mits practically unrestricted retrofittingof expansions to an existing press confi-guration.

Another advantage is the significantlyreduced on-site installation time, becauseall subassemblies can be pre-installedand tested prior to shipment.

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KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Drives

KBA DriveTronicMoney-Saving

Dedicated Drives

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C 408 C 418 C 618 C 818Circumference mm 890-900* 1,156–1,240* 1,156–1,240* 1,156–1,240*

Max. web width mm 1,260 1,000/1,075 1,450 1,905/1,980/2,060

Max. no. of pages A4 (standard) 32 short-grain 32/40 long-grain 48 long-grain 64/72/80 long-grain

Max. speed rph 60,000 45,000 45,000 45,000

Max. web speed m/sec 15 15 15 15

*additional circumferences upon request

Standard features.KBA reelstand.KBA infeed unit.Stretching roller.Printing units.Blanket washing unit.Water preparation unit.Web catcher.Dryer without after-burner.KBA chill roll stand.Superstructure with/without insertion deck

.Silicone unit

.Web guidance

. Ink-register control

.Cut-off register control

.Automatically convertible P5 folder

.Plate-punching machine

.Plate-bending machine

Opera (standard).Console (KBA ErgoTronic).Remote adjustment of inking unit, dampening unit and register (KBA ColorTronic)

.Shaftless drives (KBA DriveTronic)

.Production management system (KBA LogoTronic): basic

.CIP3 integration possible

Optional extras.KBA Patras reel-logistics system (manual or automated)

.Web-threading device

. Ink-supply system

.Dryer with integrated after-burner

.Desk lighting

.Height adjustment for desk

.Web-remoistening unit

.Cross lead for duplex presses

.Steel substructure for stacked version

. Insertion decks

.Auxiliary former

. Length gluing unit

. Format-variable V5 folder

.Cutter

.Die-cutter perforator

.Coater and remoist gluer

.Plough fold

.Compressed-air unit

.Cooling station

Opera (optional extras). Film and plate scanner (KBA ScanTronic)

.Production management system (KBA LogoTronic): professional

.On-line data transfer (KBA CIPLink)

KBA COMPACTA 408/418/618/818 Commercial Web Offset Presses Data

COMPACTA 408/418/618/818At A Glance

The KBA COMPACTA 408/418/618/818is manufactured by Koenig & Bauer AG,

which reserves the right to carry out modifications without prior notice. No part of this publication may be reproduced in any way without the manufacturer’s permission. Illustrations may depict special features not included in the basic press price.

For further information please contact our sales department at:Koenig & Bauer AGFrankenthal FacilityPostfach 1122, 67227 Frankenthal, GermanyJohann-Klein-Str.1 67227 Frankenthal, GermanyTel: (+49) 6233 873-3278 Fax: (+49) 6233 873-3595Web: www.kba-print.comE-mail: kba-frankenthal@kba-print.de03/2006-e. Printed in Germany

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