EN
Expansion of Production Capability by Utilizing High-Speed Paper Printing Machines
Revolution in Throughput: Printing on 15,000+ Sheets/Hour
Today's cutting-edge high-speed paper printing machines are capable of increasing their output from an industry standard of 5,000 sheets in one hour, to as many as 15,000 sheets in just one hour, exponentially increasing output per shift with no changes to flooring outlets or workforce. Integrated automation has enabled engineers to develop incredibly ingenious paper printing machines allowing plants to eliminate manual paper loading with an automatic paper handler, integration of printing machines with automatic paper handling machines, eliminating motion interruptions with continuous-feed systems, and maintaining mechanical registration even at rapid servo speed with peak mechanics functions. Plants adopting rapid response fulfillment with ISO 12647 standards for color registration and fulfillment of orders in as little as 60% quicker time turnarounds, now enjoy competitive advantage over their competition.
Engineering Foundations: Precise Feeding Systems, Dynamic Control of Tension, and Synchronized Systems of Control and Production
Combining Systems of Control and Production allows for:
- Laser alignment ensures the placement of each sheet within ±0.1mm and at a speed of over 30 meters per minute
- Dynamic Control of Tension adjusts the web tension of paper to eliminate jams and misregistration
- Synchronized Systems of Control and Production allows for the instant finalization of production to eliminate smudging of ink to allow production to shift seamlessly downstream.
Thanks to the synergy of the three systems, speed and reliability serve to reinforce each other. For the industry, the standard has become a loss of production by no more than 1.2% during high-volume production runs.
We Want to Cut Costs Further on Your Print Flow
Labor and Energy Savings from Medium to High Volume Business Paper Printers
We can automate cost improvements. The latest high speed machines have demand a labor cost savings of up to 40% due to the elimination of loading, adjusting, ink supply and inline finishing for the operator. Energy demand is 15-30% lower from units with high speed heat recovery systems with drying, and better control of motors on runs with more than 10,000 impressions. Real time tension control of the substrate and monitoring of the substrate also save waste. Automated ink dosing also saves waste by ensuring gapless and minimum waste coverage. As a result, medium volume production runs of 5,000-20,000 sheets moved from zero, or insignificant, production profit to solid profit production.
Total Cost of Ownership (TCO) Comparison of Traditional Contact vs. Next Generation Paper Business Printers
Modern high speed paper printing machines provide a greatly reduced total cost of ownership high to low shift, no low shift, vs. offset printers for 5+ million sheet production. The impact on paper printing (5+ million) is a reduction in total cost of ownership.
With the new production values, non productive (resource change) time is sharply reduced. The cost of setup/resource is reduced by 70%, energy/labor units and material losses are reduced (too) by 22-28%high to low shift on total cost of ownership, and estimated production unit value savings of 6 figures for high volume production).
Achieving Premium Print Quality While Optimizing Costs
Real-Time Registration, Closed-Loop Color Calibration, and Sub-50µm Dot Accuracy
When all three technologies are used, they ensure a sustainable premium print quality at 15,000 or more sheets per hour.
Real-time registration determines possible sheet position changes and uses corrective actions to address these changes ensuring aligned and perfect images for long print runs.
Inline spectrophotometers are placed to measure the quality of the print at intervals of 90 seconds. The spectrophotometers automatically alter and calibrate the ink that is flowing, the thickness of the ink, and the laying down of the ink, all while ensuring Delta E is below 1.5 and the color is within ±0.5%.
Thanks to this piezoelectric printheads and their adaptive pressure controls, we can deliver a print quality of 2400 or more dpi. That print quality eliminates distortion in halftones while delivering sharp gradients and clear text.
Ghosting, color drift, and registration errors are solved by this integrated triad. Without the need for additional resources, it meets the benchmarks set for the GRACoL and SWOP certification.
How is the cost lowered by the use of these high-speed paper printing machines?
The high-speed paper printing machines have automated requirements that lowered labor, and made ready waste, and maintenance downtime, to name a few, decreased.
How is print quality maintained at high speeds?
Real-time registration, closed-loop color calibration, and sub-50µm dot accuracy correct sheet alignment, adjust flow ink, and ensure precise placement of applied ink.