Key Specs

Equipment

Reel Splicer

• Manufacturer: Contiweb (Goss)
• Model: CS-1020 1W
• Type: Horizontal, zero-speed, shaftless splicer
• Maximum Splicing Speed: 10.5 m/s (2,070 ft/min)
• Maximum Web Width: 1,020 mm (40 in)
• Maximum Reel Diameter: 1,270 mm (50 in)
• Maximum Reel Weight: 1,600 kg (3,530 lbs)
• Web Tension Infeed: 150–1,600 N (34–360 lbf)
• Standard Core Diameter: 76 mm (3.0 in)
• Integrated electronically controlled infeed with Contiweb web guide, controlled via touch screen and Omnicon console
• Shaftless design — no core shafts required
• Automatic positioning of lifting arms for different web widths and reel positions
• Automatic splicing at any reel diameter with short overlap (approx. 50 mm / 2 in), clean cut, no tail
• Manual reel track system with 2.75 m (9 ft) of rail, manual trolley and loading platform
• Remote diagnosis via VPN through press network
• Contiweb Unpack Station for 1 web — two driven retractable rollers to lift, rotate and lower reels onto auto-load cart, with remote pendant control and integrated weighing device
• Contiweb Webdata with printer — automatic paper usage and production reporting per reel, order, job or shift; includes barcode reader

Printing Units

• Number of Units: 4
• Type: Blanket-to-blanket, in-line stacked cylinder arrangement
• Drive: Individual AC drive motors (one per unit)
• Plate Changing: Goss Autoplate — automatic plate-up system on both plate cylinders per unit, plate change without breaking the web
• Plate Cylinder Bearers: 40 mm wide hardened steel
• Plate Cylinder Undercut: 0.27 mm (for 0.30 mm aluminium plates)
• Register: Motorized lateral (± 2 mm), motorized circumferential (± 3 mm), motorized plate cocking (± 0.3 mm); unit phasing by drive synchronization
• Inking: 15 large-diameter rollers per unit (ceramic fountain roller, nylon pick-up roller, 3 oscillating vibrators, 5 distributor rollers, 3 form rollers, 1 rider roller); remote ink key control; convertible 100-0-0 / 80-10-10 split; Goss pneumatic ink scraping blades (2 per unit)
• Dampening: Convertible dampening system (film or emulsification mode), pneumatic switching from Omnicon console; integrated filtering per unit
• Blanket Washing: Baldwin IMPACT flex automatic blanket cleaning system with Prepac pre-soaked tissue, 10 selectable wash-up programs, 2 wash-up bars per unit
• Ink Supply: Technotrans Multi.fill ink leveller system with Omnicon integration, 2 constant levels per unit
• Dampening Solution / Temperature Control: Technotrans Delta c.16/60 integrated chiller for alcohol-free printing (0% alcohol); dampening circuit with stainless steel tank, filter, additive mixer, conductivity display; closed-loop ink roller temperature control with electrical heating
• Web Break Protection: Goss patented active web catcher (air knife + 2 catching rollers, >90% efficiency), installed between last printing unit and dryer; additional web severer at web catcher exit for heavier stock
• Space for 5th printing unit (located after splicer, electrical supply pre-upgraded for future retrofit)

Dryer

• Manufacturer: Contiweb (Goss)
• Model: Ecocool/T 75-1020
• Type: Heatset web offset dryer with integrated thermal afterburner (Ecotherm concept), chill section, and closed-loop colour control integration
• Maximum Speed: 8.6 m/s (1,700 ft/min) at 90 g/m² / 6.9 m/s (1,370 ft/min) at 135 g/m²
• Chill Section: 9 small-diameter chill rolls (4th roll driven by frequency-controlled AC motor)
• Web Temperature Control: Infrared camera between drying and cooling zone
• Advanced C-Control: Active solvent concentration control with frequency-controlled fans, enlarged heat exchanger with controlled bypass
• Silicone Applicator: Goss silicone applicator before 1st and 2nd chill rolls, speed-compensated, coats both sides, with reservoir and mixer
• Contiweb web guide system and web break detection in chill section
• Web tension measurement at last chill roller
• Motorized webbing-up chain through dryer and chill section
• Gas Supply: Natural gas; min. dynamic pressure 100 mbar (1.45 psi), max. static pressure 330 mbar (4.8 psi)
• Remote diagnosis via VPN
• Compliant with EN 1539, NFPA 86, VDI directives

Inkjet Printing Unit

• Manufacturer: Adphos / Kodak Prosper
• Type: Inkjet imprinting tower with 4 rails
• Print Heads: 8 Kodak Prosper print head buckets (2 per rail)
• Drying: 2 Adphos IR drying modules, each with 24 emitters
• Central control unit with PLC for carriage control and Kodak controller interface
• Provisions for future addition of 2 chill rolls to inkjet tower

UV Coating Unit

• Inline UV coating unit

Gluing System

• Manufacturer: Planatol
• Model: Opimatic CombiJet System 9DT
• Number of Heads: 4 (3 standard + 1 additional head for PFF module)
• Function: Intermittent longitudinal gluing and fold softening
• Application: Contact application with ceramic nozzles
• Memory: 29 product pictures, each with individual glue patterns
• Motorized lateral adjustment of head locations with position feedback
• Adhesive and softening agent fed from 50 kg pressurized tanks

Paper Lead and Ribbon Section

• Driven pull roll with 4 air-loaded trolleys
• Scissor-type slitter — web cut into 2 ribbons (1/3–2/3, 1/2–1/2, or 2/5–3/5); motorized slitter position
• 4 full-web-width angle bars with air hole adjustment (2 motorized, controlled from Omnicon console, positions stored for job presetting)
• 2 full-web-width motorized linear compensators with position display on console
• Optional plow fold
• 2 former folds with possibility to collect both ribbons after the main former fold and route into PFF module or into JF-48 folder
• Driven RTF pull roll with central split anvil for slitting or perforating

JF-48 Combination Folder

• Type: Single-width combination folder with quarter fold assembly
• Products: Tabloid, magazine, double parallel, delta, and digest signatures
• Circumferential perforator/scorer — in-line, manually operated, with on-the-run depth and lateral adjustment
• Cross perforator cylinders for first fold, second parallel, and delta folds; with triple cross perforation
• 1-part cutting cylinder with knife box
• 2-part transfer cylinder with 2 sets of active tucker blades, pins and cutting rubbers; on-the-run fold lap adjustment (± 12.7 mm)
• 2-part jaw folding cylinder with 4 adjustable jaw blade assemblies
• Quarter folding assembly — gear-driven vertical chopper with vacuum slowdown tables; chopper blade timing on-the-run; silenced via electromagnetic clutch
• Double parallel and delta fold cylinder — 2-part with grippers and tucking blade assemblies; can be quarter-folded
• Single-stream delivery — mechanically driven creeping belt delivery; all products spine leading, perpendicular to press centerline
• Ultrasonic jam detectors

PFF Module (Pinless Former Fold)

• Auxiliary small former attached to the JF-48 folder
• Products: 4 × 4 pages (3 sides open) or 2 × 8 pages (3 sides open)
• Maximum ribbon width over former: 510 mm (20 in)
• Minimum ribbon width in PFF cylinders: 200 mm (7.9 in)
• Demonstrable accuracy (cut to print): ± 0.5 mm
• Separate delivery conveyor under main folder tabloid delivery

Sheeter

• Manufacturer: Vits
• Model: Rotocut S
• Type: Double cut (half cut-off) sheeter
• Web Width Range: 400–1,000 mm (15.7–39.4 in)
• Cutting Accuracy: ± 0.4 mm
• Non-stop piling system
• Goss Sheeter Bypass Rollers in the folding unit allow the web to be redirected directly from the folder to the sheeter
• QuadTech cut-off control for sheeter

Postpress

• Manufacturer: RIMA
• Conveying System: Pivot conveyor, flat belt conveyors, 2 × 90° flow turns, stream aligner / divert gate, inclined waste conveyor
• Trimming: RIMA RS 830 ECO rotary trimming line with 4 knives (3 standard + 4th trimming head), bump turn to the left, vacuum-assisted delivery belt and straight-out delivery
• Stacking: RIMA RS-36S 330 mm (13 in) indexing counter stacker with right/left/alternating indexing forks, servo pusher, pneumatic turntable, 762 mm (30 in) infeed extension
• Press Interface: Product speed sensing with encoder, divert control, remote emergency stop

Control Station

• Goss Omnicon Control System — PLC-based Master Press Console combining press control and colour control from one station; controls all print, fold and drive functions
• Touch screen monitors, pull-out keyboard/mouse trays, multiple language support
• Consoles: 1 Master Omnicon console (with colour control) + 1 additional Omnicon press console for units + 2 auxiliary equipment consoles
• Register Control: QuadTech RGS IV MultiCam for 1 web 4/4 — automated lateral and circumferential colour register control with motorized camera transport bar
• Colour Control: QuadTech Closed-Loop CCS Icon with solid ink density — 2 scanning CCD video densitometer cameras (1 per side), continuous web scanning
• Cut-Off Control: QuadTech MultiCam for 1 web or 2 ribbons + 2 additional cut-off controls for PFF + 1 for sheeter
• Prepress Interface: Goss Web Center with Prepress Interface (CIP3 format)
• Remote diagnostics via modem

Possible Signatures

JF-48 Folder

PFF Module

Sheeter (Rotocut S)

Technical Details