Exact, efficient, and energy-saving - Heidelberg’s new CombiStar 3000 and CombiStar 3000 Pro inking unit temperature control. New Article Series, Part IV. By Hilde Weißer
Star Peripherals from Heidelberg
The Heidelberger Druckmaschinen AG (Heidelberg) Star System covers the whole system solution incorporating peripherals for Speedmaster presses. The key peripherals are linked to the press via the Prinect CP2000 Center control station by means of a CANopen data bus CAN = Controller Area Network).
Schematic diagram of the CombiStar 3000.
In the first three articles in the series devoted to peripherals, we presented the AirStar 3000 air supply, CoatingStar coating supply, InkLine 3000 ink supply system, and the DryStar 3000 and DryStar 3000 UV drying systems. Part four deals with the CombiStar 3000 and CombiStar 3000 Pro, the new system for inking unit temperature control and dampening solution preparation. These can all be found lower down in this Technology-related features section. Part III appeared in July of this year.
High-precision control thanks to extended CANopen link For the first time, press data is used via CANopen on the CombiStar 3000 to regulate inking unit temperature control, thereby significantly cutting waste. The new high-end CombiStar 3000 Pro system for the Speedmaster XL 105, Speedmaster SM 102, Speedmaster CD 102 and Speedmaster CD 74 ensures consistent printing conditions through enhanced filtration, metering, and analysis techniques and provides a major boost to saving energy. As well as the potential savings through the water-cooled peripherals, the CombiStar 3000 Pro can save up to 8,000 Euro per year in double-shift operation, with reductions in energy consumption of approximately 3,000 Euro and filtration savings of around 2,500 Euro. Precise alcohol metering can bring savings of approximately 2,000 Euro, and accurate metering of dampening solution additives can result in savings of over 500 Euro.
‘Every press manufacturer today has inking unit temperature control and there are enough suppliers specializing in this business,’ explained Bernd Thuerauf, Product Manager for peripheral systems at Heidelberg. ‘That’s why we don’t build them ourselves but ensure they are integrated properly. We thus always combine inking unit temperature control with our own, highly efficient distributors in the printing unit. Another unique feature is that the system is controlled via CANopen,’ added Thuerauf.
Efficient temperature control using efficient ink distributors Instead of simply squeezing cooling water through a hollow ink distributor - as most other suppliers do - Heidelberg equips its presses with efficient ink distributors. These incorporate a second cylinder into the hollow of the distributor and the cooling water is squeezed through the small gap between the inner and outer cylinders. This accelerates water flow and much more heat can be dissipated.
For the first time, the ink fountain roller is controlled on the Speedmaster XL 105 via a separate temperature control circuit, enabling the ink on this roller to be kept warmer than in the inking unit itself. This results in a perfect and more consistent flow of ink into the press. A greater but highly consistent temperature on the fountain roller is particularly beneficial for highly viscous UV inks in order to achieve consistent colour quality throughout a job.
CombiStar 3000 - enhanced temperature control through intelligent closed loop The CombiStar 3000 represents a further successful step by Heidelberg toward high consistency printing conditions. For the first time, the CombiStar 3000 queries the press status via CANopen and detects whether the press is running or is at a standstill, whether there is a press stop, and what production speed the press is achieving. This information is incorporated into the inking unit temperature control process and augments the measurements using temperature sensors in a closed loop. Customers benefit from the fact that, when the press is stopped and started up, the CombiStar 3000 can respond faster than any other system. This results in fewer waste sheets and consistent ink density.
CombiStar 3000 Pro - new high-end version for stable printing conditions As well as the conventional CombiStar 3000, Heidelberg now offers a new high-end device, the CombiStar 3000 Pro, on the Speedmaster XL 105, Speedmaster SM 102, Speedmaster CD 102 and Speedmaster CD 74. This adds further functions to ensure an even more consistent printing process, save energy, and cut operating costs. Heidelberg particularly recommends these systems for all UV users but also for the use of metallic inks, opaque white, and reduced-alcohol operation.
Schematic diagram of the CombiStar 3000 Pro.
The most important additional component on the CombiStar 3000 Pro is integrated, two-stage dampening solution filtration. In the past, Heidelberg tested various systems and selected the best. Bernhard Konz from the Engelhardt & Bauer print shop in Karlsruhe, Germany, said, ‘Normally we change the dampening solution on our press every four weeks. Since installing the CombiStar 3000 Pro, this cycle has been extended to six months. Each year, this saves us 2,500 Euro in disposal costs and press downtimes.’ The system is designed so that all coarse dirt particles such as paper coating are trapped in the pre-filter. This filter is cost-effective and can be changed within minutes. The main filter picks up the finer elements, and the filters are normally changed only once a year. Ralf Dombrowski from the Paffrath print shop explained, ‘We have been trying for years to cut the alcohol concentration in the dampening solution. We made the breakthrough in 2005 with the installation of the new dampening solution filtration cabinet. Since then, we have been able to work with nought per cent isopropanol (IPA) in the dampening solution without any major additional cleaning.’
As well as dampening solution filtration, the CombiStar 3000 Pro boasts a new digital metering pump that meters the dampening solution additive with an accuracy of +/- 0.1 per cent. Users are supported by versatile sensors, consumption data capture, and computer-supported trend analysis. They can read off all relevant process parameters on a colour display and, for example, obtain the temperature profile and pH or conductivity value over the last few weeks in graphic form. This supports printers when deciding to change the dampening solution in good time.
Intelligent energy saving Free cooling is a unique feature that the CombiStar 3000 Pro uses to cut energy consumption. Climatic conditions in Germany enable the inking unit temperature control in the CombiStar 3000 Pro to be operated for up to 73 per cent of the year without using the integrated cold unit. The press’s inking unit is supplied directly from a free cooler. The cold unit is only activated at temperatures well over 20 degrees Celsius. This control technology saves the printshop at least 3,000 Euro in electricity costs each year.
All necessary components, including the frequency-controlled recooling pump, are integrated into the cabinet. Installation is simple and saves time. Two pipes need to be laid between the CombiStar 3000 Pro and free cooler outside the printshop. Further investment is not required. As the peripherals and free cooler are designed for each press, they can be resold later as a package.
CANopen JDF and Prinect network prepress, press, and postpress, while CANopen connects the press peripherals. With the new CombiStar 3000, Heidelberg employs the CANopen network to continuously check the status of the press, enabling the inking unit temperature control to be regulated more accurately. CANopen also simplifies operation of Star peripherals, with all settings being made at the touch of a button via the central Prinect CP2000 Center press control system. The preset functions allow peripheral presettings to be saved with the job and accessed quickly for a repeat job. CANopen also enables the Heidelberg Remote Service to access peripherals.
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