KOMORI Packaging Solutions

Thursday , March 12 ,2015

On March 12, a packaging open house based on the theme ‘KOMORI Packaging Solutions’ was held at Komori’s Tsukuba Plant and the Komori Graphic Technology Center (KGC). This open house, held mainly for overseas customers considering a packaging press (96 customers from 15 countries), consisted of a seminar, factory tour, printing demonstration, KGC tour, a lecture by a customer as well as a party and allowed participants to experience Komori’s ‘Packaging Solutions.’

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[Packaging Seminar ・ Demonstration Points]

・Lineup of Komori package printing presses
Power of Komori products for the packaging industry, the segment with the most favorable future in the printing markets in recent years (Chambon presses, sheetfed offset presses and digital printing systems)

・Lithrone GX series concept
High productivity with heavy stock in long runs by means of stable high-speed operation
Smooth short makereadies even when using special colors
High print quality to meet the needs of high quality printing
Many variations with a range of configurations and specifications
Reduced environmental impact and superior operability

・Systems that support high packaging productivity and high quality
Significant improvement of print quality and productivity as well as reduced paper waste are realized by coordinating PDC-SX (color control/automatic registration/Smart Feedback), which advances high level print quality control by digitizing print quality, and PQA-S (print quality inspection/color control) with the KHS-AI integrated control system. In addition, the Lithrone GX40 is equipped with the following systems for packaging that are indispensible for maintaining and ensuring high print quality.

①KHS-AI (KHS system with self-learning)…In addition to air and register presets, coordination with PDC-SX and PQA-S is improved. Previous settings are quickly recalled, improving repeat jobs, which are frequent in package printing.

②PDC-SX (Spectral Print Density Control SX Model)…Uses color correction function that enables accurate feedback even with special colors. Equipped with a function that facilitates the die cutting process by adjusting the print image to the paper position.
* As an option, may be equipped with the PDF comparison function that compares the image of the printed sheet that has been scanned in with the original PDF.

③PQA-S (Print Quality Assessment System for Sheetfed)…Can be specified with a sheet numbering system that prints a number on each sheet on the feeder board and a quality management system based on package die-cutting data in units of blanks.

・Highlights of the day’s demonstrations
High speed nonstop operation for long runs
Improved operability and time reduction for changeovers of short runs and color changes
Stable quality in high speed operation (color variations, circumferential gradations, streaking and ghosting)
Strengthened inspection system (in-line inspection/PDF comparison)
Printing on both sides of heavy stock

First, in the seminar rooms a seminar on packaging solutions was held, and the main points of the day’s demonstrations were explained. The presentations were made in English, Chinese, Korean and Japanese in separate seminar rooms.

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In the afternoon, the visitors saw a printing demonstration of the Lithrone GX40 (GLX-640+C). All narration of the demonstrations was provided by Mr. Doug Schardt of Komori America Corporation, and the overall emcee was Ms. Yasuko Nakajima.

■Demonstration 1. Six-color 40-inch sheetfed offset press LITHRONE GX40 (GLX-640+C)
①JOB1
Package printing of pharmaceuticals boxes (five colors plus varnish)
Stock: El Card 26.5 kg/Shiroku-han (1,050 x 750 mm); sheet thickness: 0.35 mm
Maximum printing speed: 18,000 sph

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・The press performed initial package printing of pharmaceuticals box packaging with plates that had been mounted in the press ahead of time.

・After checking colors and register, the press printed 500 sheets at 18,000 sph without any adjustment

During the run, the measurement results from PQA-S, which has a print quality inspection function and a color control function, were shown on the operation stand monitor (KID) in real time for confirmation of the automatic feedback function.

②During job changeover (removing, blanket washing/preinking, plate changing by Full-APC (Fully Automatic Platechanger), change of printing paper, test printing, register adjustment and color matching by PDC-SX, and OK sheet), the various integrated control systems, starting with the KHS-AI (Advanced Interface) integrated control system, were explained.

③JOB2
Package printing of confectionery boxes 2,000 sheets (five colors + varnish) Stock: El Card 36 kg/ Shiroku-han (1,050 x 750 mm); sheet thickness: 0.45 mm Maximum printing speed: 18,000 sph

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・Test printing of image with heavy ink coverage and printing of 2,000 sheets after checking colors and register.

During the run, print quality inspection and density control by PQA-S were shown on the KID monitor in real time. The nonstop operation system, which maintains production at the maximum printing speed during pile changes, was also shown. After the demonstration of the Lithrone GX40, the newly added control systems were explained. The visitors then moved to KGC and saw the demonstration of the Lithrone GX40RP (GLX-840RP).

■Demonstration 2 / Eight-color 40-inch reverse printing sheetfed offset press LITHRONE GX40RP (GLX-840RP)
①JOB1
Package printing of gift boxes 200 sheets (front, four colors; back, two colors)
Stock: El Card 15.5 kg/K size; sheet thickness: 0.3 mm
Maximum printing speed: 16,500 sph

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・The press performed initial package printing of gift box packaging with plates that had been mounted in the press ahead of time.

・After checking colors and register, the press printed 200 sheets at 16,500 sph.

※The LITHRONE GX40RP is a 40-inch double-sided sheetfed offset press that uses an arrangement featuring single-edge gripping and the elimination of sheet reversal. Due to single-edge gripping, the margin on the tail edge of the sheet that is necessary with perfectors is not needed, so paper costs can be held down. Thanks to the cylinder configuration of four double-size transfer cylinders without sheet reversal, the press offers stable transport of paper with high print quality in package printing. In addition, both front and back plates are imaged in the same direction, just as with a single-sided straight press, so plate imposition and operation are very efficient.

②Job changeover (removing, blanket washing/preinking, plate changing by Full-APC (Fully Automatic Platechanger), test printing, register adjustment and color matching by PDC-SX, and OK sheet)
The changeover tasks were performed automatically by the Smart Sequence system of KHS-AI and plate changing was completed in 1 minute 25 seconds by A-APC. After test printing, front and back register and colors were checked by PDC-SX and the press performed production printing. Even if the densities are off, automatic feedback to the press by the PDC-SX color control function allows production printing to be started right away. The changeover time was 3 minutes 11 seconds.

③JOB2
Package printing of gift boxes 400 sheets (front, four colors; back, one color)
Stock: El Card 15.5 kg/K size; sheet thickness: 0.3 mm
Maximum printing speed: 16,500 sph

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・The press printed 400 sheets of the gift boxes with the heavy ink coverage image on 0.3 mm stock.

During the print run, the narrator explained the H-UV innovative curing system that was equipped on the press and the PQA-S Print Quality Assessment System that is mounted on two positions of the press for the front and back sides of the sheets. After the demonstration of the Lithrone GX40RP was finished, the demonstration of the Lithrone S29 (LS-629+C.) that was set up on the opposite side of the room was started.

■Demonstration 3 / Six-color 29-inch sheetfed offset press LITHRONE S29 (LS-629+C)
①JOB1
Package printing for cosmetics product 200 sheets (four colors plus varnish)
Stock: El Card 15.5 kg/K size; sheet thickness: 0.3 mm
Maximum printing speed: 16,000 sph

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・The press performed initial package printing of cosmetics box packaging with

・After checking colors and register, the press printed 200 sheets at 16,000 sph without any adjustment.

②Job changeover (removing, blanket washing/preinking, change of printing stock, plate changing by Full-APC (Fully Automatic Platechanger), test printing, register adjustment and color matching by PDC-SX, and OK sheet)

③JOB2
Package printing for cosmetics product 200 sheets (four colors plus white)
Stock: PET/K size; sheet thickness: 0.3 mm
Maximum printing speed: 10,000 sph

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・After test printing and checking of colors and register, the press printed 200 sheets at 10,000 sph.

After the demonstrations were completed, visitors toured KGC and were able to freely inspect the machines. In addition, a business model that makes use of a digital printing system was also explained. A commemorative photograph was output on the Impremia C80 in KGC that visitors could take home after the party. After this, visitors returned to the seminar room and received a lecture by Yoshihide Yumoto, president of Grapac Japan Co., Inc., a company with expertise in package printing.

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Finally, the group of visitors toured the Tsukuba Plant and then went by bus to a hotel, where a party was held. At the site of the party, a ceremony was held commemorating the fact that the number of visitors to the Tsukuba Plant had exceeded 20,000 visitors with this open house. After a drawing, souvenir gifts were presented to customers from Sri Lanka, Korea and the U.S.

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Komori is grateful that many people from all over the world took an interest in KOMORI packaging solutions and came to the open house. Perfectly equipped to meet a range of requirements, including an automatic nonstop operation system and control systems/automation for long runs at high printing speed, the LITHRONE GX40/ LITHRONE GX40RP presses seen at today’s packaging solutions open house will meet a wide range of needs in package printing in the years ahead. Count on Komori solutions for the future.