Rapida 105 PRO

Feeder and infeed

Bogenanleger der Rapida 105 Pro
DriveTronic feeder

  • High-performance feeder head with simple handling
  • Feeder motions controlled via 4 servo motors
  • Continuous, stepless pile lifting with automatic speed compensation (paper/board)
  • Automatic, speed-compensated air settings
  • Antistatic rear-edge separating air
  • Automatic format setting
  • Automatic pile side edge alignment
  • Front-edge pile height sensing with automatic compensation of the feeder head height
  • Skew-sheet correction at the feeder head during production
  • Quick-start function

Suction-belt feed table

  • Centre suction belt without roller arm
  • Electronically controlled sheet deceleration
  • 4 suction chambers with individual vacuum regulation

Vacuum side lay

Marking-free alignment process

Multi-chamber vacuum system to permit matching to different substrates

Included in automatic format setting

Infeed

  • 100% preset capability
  • Remote-controlled parallel and skew adjustment of the feed line
  • Remote-controlled adjustment of the front lay cover height
  • Touchscreen display with direct function keys for reliable and intuitive press operation

Sheet monitoring

  • Ultrasonic double-sheet detector, also for inhomogeneous materials
  • Multiple-sheet detector
  • Optical skew-sheet and side lay sensors
  • Optical front lay sensors with electropneumatic overshoot blocking
  • Mechanical crash bar

Non-stop operation at the feeder

  • Fully automatic non-stop feeder with rake system in conjunction with KBA PileTronic
  • Non-stop system with individual rods for uninterrupted production during pile changes
  • Pile insertion and removal possible from all three sides

Perfecting

Sheet travel

  • Gentle, air-cushioned sheet travel with blower systems and Venturi guide plates
  • Automatic setting of the substrate thickness
  • Removable sheet guide plates

Universal gripper system

  • No adjustments required to accommodate changes in substrate thickness
  • Coated gripper tips and structured gripper pads for maximum holding force
  • Gripper pads and tips can be replaced individually
  • Increased gripper shaft diameter

Register setting

  • Remote setting of lateral, circumferential and diagonal register
  • Diagonal register achieved by tilting the transfer drums
  • ErgoTronic ACR for automatic and exact register checking and correction

Perfecting

  • Proven three-drum configuration for exact perfecting register
  • Special perfecting drum gripper system handling a broad substrate range
  • Fully automatic conversion between straight and perfecting mode in approx. 2 minutes
  • Twisting suckers spread the rear edge of the sheet tight on the storage drum

Sheet guiding after perfecting

  • KBA Jackets on the impression cylinders
  • Anti-marking coat on the drum shells
  • Venturi sheet guide plates
  • Air settings made at the ErgoTronic console can be saved and recalled for repeat jobs
  • Sheet travel sensor
  • Video system to observe sheet travel in the delivery

Available perfecting configurations

  • All variants (without coating) up to 10 printing units
  • Special configurations upon request

Inking unit

Walzenstuhl Rapida 106 A4
DriveTronic SRW (Simultaneous Roller Wash)

  • Inking unit incorporating dedicated drive technology
  • Roller washing parallel to other makeready processes (except plate change)
  • Independent roller washing, also during production
  • Extreme makeready savings

ColorTronic ink duct 

  • Ink-repellent coating EasyClean
  • Makeready shortened by up to 50%
  • Ink keys with carbide blades and ceramic-coated ink duct roller
  • Remote control of the ink keys
  • Wear-free ink metering ensures accurately reproducible settings
  • Ink duct roller speed compensated to the press speed

Inking unit

  • Faster-reacting inking unit
  • Remote setting of vibrator frequency and blocking from the control console
  • Ink train separation with impressionoff
  • Automatic adjustment of the oscillation timing from the control console
  • Ink forme roller oscillation
  • Inking unit temperature control for duct roller and oscillating distributors
  • Individual engaging/disengaging of inking units from the console for reduced roller wear and minimised makeready times
  • Simultaneous washing of blanket and ink rollers

Dampening unit

  • New, speed-compensated Varidamp film-type dampening unit for a stable ink-water balance
  • Skewing of the dampening duct roller to adapt dampening solution distribution across the press width
  • Differential drive to eliminate hickeys, activated from the control console during production

Plate change

Plattenautomat final
SAPC (Semi Automatic Plate Change)

Automated plate change

  • Pneumatic opening and closing of the plate cylinder guard
  • Automatic rotation to the change positions
  • Automatic clamping and tensioning of the plate
  • Divided rear plate clamps

FAPC (Fully Automatic Plate Change)

Fully automatic plate change

  • Automatic plate change on the whole press after program start at the control console
  • Parallel changing in several printing units, completed in 3 cycles
  • New, optimised change process with change time of 2.8 minutes, including register zeroing
  • Divided rear plate clamps

Register setting

  • Remote setting of lateral, circumferential and diagonal register
  • Diagonal register achieved by tilting the transfer drums

Washing systems

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CleanTronic roller washing

  • Individual programming and central control of washing programs

CleanTronic blanket and impression cylinder washing

  • Swing-action washing beam for combined blanket and impression cylinder washing
  • Individual programming and central control of washing programs
  • Parallel washing of rollers and blanket
  • Use of dry cloth or ready-impregnated cloth rolls
  • Indication of washing cloth consumption at the control console

CleanTronic Multi

  • Multiple-media washing system permitting the use of different ink systems
  • Separate solvent circuits permitting fully automatic switching from conventional to UV inks
  • Fast system switching (between conventional and UV)
  • System and washing program selection at the control console

"PrintClean" function

  • Targeted stripping of the remaining ink from plate and blanket (using a preselected number of sheets)
  • Reduced blanket washing times and material consumption
  • Can replace blanket washing for short runs

CleanTronic UV

  • WashTronic safety function to eliminate waiting times before and after cylinder washing in UV mode
  • More efficient makeready and longer service life for UV lamps

DriveTronic SRW

  • Dedicated drive technology for roller washing completes a comprehensive system for the automation of washing processes

Coater

Lackwerk final
Chamber blade system

  • Hydropneumatic control for constant and even coating application
  • Lightweight anilox rollers ensuring fast and user-friendly replacement

Coating supply system with 100% console integration

  • Fully automatic cleaning for dispersion and UV coatings
  • Cleaning time: Simple coating change in approx. 1 to 2 minutes (dispersion dispersion; UV UV)
  • Cleaning time: Complete coating change in approx. 8 to 10 minutes (dispersion UV)
  •  Central control via the press console

IVL sensor (Intelligent Viscosity Logic)

  • Coating level monitoring and viscosity-dependent pump control
  • No more risk of coating starvation

Coating forme change

  • Universal clamps for blankets and coating plates
  • Quick-release clamps for coating plates with register system for automated forme change (change time: 1 minute)
  • Remote pressure setting
  • Remote adjustment of lateral and circumferential register from the press console

Delivery

Auslage final
Sheet travel

  • High-level delivery for smooth sheet transport
  • Touchscreen display with direct function keys for reliable and intuitive press operation
  • Venturi air-cushioned sheet guiding
  • Speed-compensated gripper opening cam for a broad range of substrates
  • Fan modules and blower bars promote optimum pile formation
  • Standard-compliant light barriers to guard the hazardous area    

Powder sprayer

  • Speed-compensated and format-dependent powder metering
  • Possibility for integration of powder extraction

Sheet brake

  • Suction roller with pre-suction plate and variable speed to facilitate smooth sheet delivery
  • Suction rings can be deactivated in pairs

Sheet brake for perfector presses

  • Dynamic sheet brake with speed-compensated suction belts
  • Maximum utilisation of the sheet format when printing on the reverse
  • Automatic format adjustment for the suction belts
  • Deactivation of individual suction modules from the console
  • Substrate-dependent control of suction power
  • Simple replacement of suction modules

Emission Extraction System EES

  • Extraction of emission-laden air from the delivery

Extended delivery

  • Extension length 2,400 and 3,800 mm
  • Enhanced productivity when coating thanks to longer time for drying

Non-stop operation at the delivery

  • Non-stop pile change possible at full production speed
  • Lowerable non-stop roller rack extended automatically above the main pile
  • Sensor monitoring for lifting/lowering of main and auxiliary piles
  • Alternative: Non-stop system without lowering capability for smaller pile heights or several product piles on a single pallet

Drying systems

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VariDry IR/hot air

  • IR/hot-air drying with stepless control
  • Can be installed as final dryers, as intermediate dryers or in a dryer tower
  • Carbon twin lamps with IR power rating of 60W/cm
  • Lamp replacement without tools
  • Dryer control on the basis of pile temperature

VariDryBlue

  • System variant for enhanced energy efficiency
  • Energy saving potential up to 50% compared to conventional IR/hot-air dryers
  • Unsaturated dryer air recirculated within the extended delivery
  • Controlled via the press console    

VariDry UV

  • Compact dryer module with UV power rating of 160 W/cm (stepless control)
  • Can be installed as final or interdeck dryers
  • Lamp replacement without tools
  • Automatic pile temperature measurement
  • Lamp-specific acquisition of operating hours, irrespective of installation position
  • CleanTronic UV to shorten the waiting times when washing

VariDry HR-UV

  • Use of specially doped mercury lamps in a flexible modular system
  • Lamps matched precisely to highly reactive inks
  • Stepless adjustment of the lamp power between 80 and 200 W/cm
  • Reduced energy costs through jobspecific setting of the lamp output
  • A single HR-UV module is sufficient for the curing of up to 5 highly reactive inks printed "wet-in-wet"
  • Ozone-free HR-UV lamps eliminate the need for emission extraction systems in the delivery
  • Fast and simple module exchange thanks to reliable, plug-in media connectors
  • Universal KBA dryer module design allowing the use of different UV lamps

VariDry LED-UV

  • UV lamps in flexible modular design, using light-emitting diodes
  • No maintenance expense
  • Wavelength matched exactly to special, highly reactive LED inks
  • No warm-up phase and no standby mode necessary
  • UV output can be adjusted to the format width and length
  • Very long service life
  • Mercury-free
  • Minimal heat input into the print substrate
  • Same scope of applications as HR-UV dryers

Console and Workflow management

Leitstand final
ErgoTronic

  • Wall screen for visualisation of all press settings   
  • Live image from QualiTronic ColorControl on wall screen   
  • ColorTronic ink metering with ink profile displays on console   
  • Integration with existing DensiTronic professional possible   
  • Sheet inspection desk with adjustable desk angle   
  • Motorised console height adjustment with memory function   
  • USB port for fast communication of job data   
  • Uninterruptible power supply to enable controlled press shutdown in case of power supply failure
  • Integrated remote maintenance module KBA PressSupport 24 Sheetfed with Internet link for remote maintenance and software updates   

Control console functions (dependent on incorporated options)  

  • Job changeover program JobAccess for automatic job presetting   
  • Job-specific saving of all relevant press parameters for repeat jobs   
  • Remote register setting
  • Control for all peripheral equipment
  • Maintenance indicator and print-outs of maintenance lists   
  • Unbroken production data acquisition in conjunction with LogoTronic Professional   
  • Creation and printing of pile dockets
  • Preview images 

New TouchTronic operating functions  

  • Touchscreen for intuitive access to all press functions   
  • Less start-up waste thanks to new functions to establish ink profiles   
  • All operating functions accessible with no more than 2 clicks   
  • Job list with preview images and functions for job order optimisation based on ink coverage data   
  • Uncomplicated handling of spot colours   

Job changeover program "JobAccess"  

  • Preparation of the next job while production is still running   
  • Makeready savings up to 50%
  • Automatic execution of all preselected makeready processes in time-optimised order   
  • Presetting of format and Substrate thickness   
  • Presetting of all substrate-specific air settings   
  • Job-specific presetting of ColorTronic ink metering   
  • Preselection and activation of washing  functions   

ErgoTronic console with integrated measuring systems  

In addition to the standard ErgoTronic features   

  • Sheet inspection desk as vacuum board with fixed desk angle   
  • ErgoTronic ColorDrive and ColorControl for density and Lab measurements   
  • ErgoTronic ACR and ICR for Register control   
  • Integration of Instrument Flight for extended colour control according to grey balance

CIPLink

  • Ink profile presetting via CIP3 data

LogoTronic Professional  

Comprehensive management system for KBA presses:   

  • CIP3/CIP4 interface to prepress
  • JDF/JMF or XML interface to an MIS
  • Order management
  • Press presetting
  • Master data, including central colour database   
  • PressWatch for graphic representation of the overall production process   
  • SpeedWatch for graphic representation of job progress   
  • Automatic saving and management of all quality reports

Logistics systems

Drucksaal b
Non-stop operation at the feeder

  • Non-stop system with individual rods for uninterrupted production during pile changes
  • Fully automatic non-stop system with sensor-monitored rake for pile transport and pile reunion
  • Pile insertion and removal possible from all three sides

Non-stop operation at the delivery

  • Non-stop pile change possible at full production speed
  • Lowerable non-stop roller rack extended automatically above the main pile
  • Sensor monitoring for lifting/lowering of main and auxiliary piles

PileTronic

  • Networking of press control, nonstop pile changing systems and pallet supply for efficient print production
  • Proven logistics modules
  • Elaboration of customer-specific solutions
  • Pallet-free paper supply possible

Technical data

Sheet format:

Maximum (straight/perfecting mode)

740 x 1050 / 740 x 1050 mm

Special format (straight)

750 x 1050 mm

Special format (straight)

780 x 1050 mm

Minimum (straight/perfecting mode)

360 x 520 / 400 x 520 mm

Print format:

Maximum (straight/perfecting mode)

730 x 1050 / 720 x 1050 mm

Special format (straight)

740 x 1050 mm

Special format (straight)

770 x 1050 mm

Substrates 1):

Standard

0.06 – 0.7 mm

with board-handling package (from approx. 450 g/m2)

up to 1.2 mm

with corrugated package

up to 1.6 mm

Perfector press

up to 0.7 mm

Gripper margin

10 mm

Production speed 2):

up to 9 printing units with coater or 10 printing units

17,000 sheets/h

Perfector press up to 10 printing units in straight mode

17,000 sheets/h

Perfector press up to 10 printing units in perfecting mode

15,000 sheets/h

Pile heights from floor:

1,250 mm

Feeder

1,250 mm

Delivery

1,200 mm

Feeder in non-stop operation

1,000 mm

Delivery in non-stop operation

900 mm

Standard plate and blanket dimensions (format length 750 mm):

Plate size

795 x 1050 mm

Standard copy line

36 mm

Blanket size

860 x 1060 mm

Special plate and blanket dimensions (format length 780 mm):

Plate size

850 x 1050 mm

Standard copy line

43 mm

Blanket size

880 x 1060 mm

1)
Printability is also influenced decisively by the flexural rigidity of the substrate
2)
Dependent on individual processing parameters, e.g. the inks and substrates used