Manroland Lithoman IV 72/80pp

Overview:

• Cutoffs: 620mm (24.41") AND 413mm (16 1/4")
• Width: 2060 mm (81")
• 72/80 pages
• Megtec Reel Splicer
• 4 colors
• Contiweb Dryer Ecoset/T (2018)
• Folder 1 - Long Grain: 2x Formers, 2:5:5, 1x Cross Fold with 2 deliveries, 2x longitudinal folds with 2 deliveries
• Folder 2 - Short Grain: 1x Former, 3:5:5, 1x Cross Fold with 2 deliveries and cylinder stitcher
• Machine in excellent condition
• Located in Germany
• can be inspected in Production

Details

Reel Transport System

• Fully automatic reel loading system MAN Roland AUROload 2.1 for the Megtec splicer
• Approx. 3 m driven reel feed track ahead of the unwrapping station, approx. 4 m driven reel feed track, approx. 3.2 m driven residual reel track
• 2 transport carriages
• Unwrapping station with integrated weighing device
• Traversing platform (Schiebebühne) for automatic reel pick-up by the splicer
• 2 residual reel adapters, core container on transport carriage
• Control for automatic reel feed operation, safety guarding at the splicer
• Reel data terminal (RDT) with full-graphic touch panel: reel data entry/display, data interface to splicer and printnet PressManager (PPM), reel list in the ProductionReport

Reel Splicer

• Type: DLC 3200 Automatic (MAN Roland / Megtec), single-web
• Integrated infeed unit
• Split support arms for simultaneous clamping of reels of different widths
• Belt-less reel acceleration and braking in the rotation axis (DC motors, 4-quadrant drive)
• Automatic support arm adjustment
• Web guiding and guide rollers, PECOM control, AUROload 2.1 control

Infeed Unit

• Support stand ahead of the 1st double printing unit with web tension measuring roller, Baldwin clamp-and-cut device, spreader roller and concave spiral guide roller
• Automatic web lead-in system MAN Roland "finite chain" (endliche Kette) from the reel in the splicer up to the slitter ahead of the turner bars, threading speed 50 m/min / 164 ft/min

Printing Units

• 4 double printing units (blanket-to-blanket), 4/4
• Automated plate changing PPL (Power Plate Loading) with automatic plate clamping and exact plate cylinder positioning
• Disengageable film inking units
• Hydromix dampening units with ceramic-coated dampening distributor (Hydrocer)
• Separate temperature control of ink fountain roller and distributor rollers
• Motorized diagonal, circumferential and lateral register adjustment
• Water-cooled AC individual drives (shaftless), system AutoCycle
• 4 image register compensator units (Bildregler): 5 mechanical compensators below the web ahead of unit 1; 5 mechanical/pneumatic compensators below and 4 pneumatic compensators above the web ahead of units 2–4
• 4 ink doctoring (anti-emulsification) devices for the ink transfer roller when printing partial-width webs
• Automatic ink roller washing system Baldwin APW for 4 double printing units
• Automatic blanket washing system for 4 double printing units, with automatic wash cycle selection after reel change
• Colour register control MAN Roland CRC-S, cameras in the folder superstructure
• Web catcher and web break protection Baldwin Webcatcher S18i with DSA (Dynamic Sensor Adjustment)

Dryer

• Hot-air dryer Contiweb Ecoset/T 146-2060 without chill section (2018), web offset dryer with integrated afterburner
• Drying section 14.6 m / 47.9 ft with 4 hot-air zones, two zones with hot-air flaps; former cooling zone used as additional dwell zone
• Individual recirculation motors per web side
• Active negative-pressure control, improved fresh/hot air mixing in the last section, increased sealing and insulation, combustion chamber with by-pass in the heat exchanger area, burner heads with extended control range and monitoring
• Burner system to EN 1539 and NFPA 86
• Max. web speed 14.6 m/s / 2,874 ft/min (at 120 g/m²); web width 1,030–2,060 mm / 40.55–81.10 in; max. ink coverage 1.93 g/m² per side
• Installed gas capacity 2,100 kW; electrical connection 380–400 V / 50 Hz, 442 kVA, max. operating current 637 A, main fuse 800 A; compressed air 6–16 bar
• Dimensions L × W × H 15,292 × 5,902 × 3,112 mm / 50.2 × 19.4 × 10.2 ft; weight approx. 40,000 kg / 88,200 lb
• Contiweb Ecochill 2060 (2018) mounted on the existing chill roll group: 3 chill rolls connected to the existing cooling circuit, 2 silicone application rollers connected to the existing circuit, connection structure for the dryer's lower and upper fresh air intake through the chill roll area (no condensation on chill rolls, no fumes in the press hall), web lead-in device; chill roll capacity 90 kW; remoistening 2.5–4.5 % by weight; 615 × 3,200 × 875 mm, 1,100 kg / 2,425 lb
• Chill roll stand MAN Roland: 6 chill rolls (1st chill roll concave), 3-circuit cooling system
• Chill roll cleaning system MAN Roland / Baldwin for the first chill roll
• Remoistening system Eltex Webmoister 70 XR with Moistrex MX 5000E-T80 moisture measuring device
• Colour density control GMI ColorQuick: support stand between chill stand and folder superstructure, additional web break detection, Erhardt & Leimer web guide, PECOM interface, density correction via ColorDesk, level 2 Spectral Reporting Connection, Tone Value Analysis (Creo Prinergy)

Folder Superstructure

• Single-web superstructure, guide rollers concave/spiral up to the slitter, cylindrical thereafter (rough-chromed before silicone application, smooth-chromed after)
• Web tension measuring roller and Erhardt & Leimer web guide for the full-width web
• Silicone applicator MAN Roland-Weko WFG 1.4 with automatic speed adaptation and vacuum-plasma-treated application roller
• Slitter with 4 slitting units dividing the web into 5 ribbons, motorized and presettable
• Motor-driven draw roller with nip roller
• 5 pairs of turner bars, motorized and presettable
• 5 Erhardt & Leimer ribbon guides, 5 ribbon tension measuring rollers, 5 driven ribbon draw units, 5 cut-off register adjustment devices
• Longitudinal gluing and softening unit Planatol Combijet 8 MOD with container supply, extended to Multijet: 7 + 1 + 5 application heads for intermittent gluing (incl. collective glue head in FE02), console-integrated
• Electrostatic ribbon blocking (Eltex)
• Main former: driven former roller with tensioning rollers and centre slitter; motorized longitudinally adjustable bar former with crowned former nose and anti-wrinkle roller, former adjustment left to right
• Second small former beside the main former (former tips flush): paper guiding for 2 ribbons, 2 Erhardt & Leimer ribbon guides, 2 tension measuring rollers, 2 driven draw units, 2 cut-off register devices, driven pre-former roller with centre slit, driven former roller, bar former with crowned nose, longitudinally adjustable together with the main former; CutControl C extension with 2 additional scanning heads
• Ribbon lead from the main former to folder FE01: draw unit below the former, draw unit after merging the former ribbons, electrostatic ribbon blocking Eltex GHH 36 (rod electrodes)
• Ribbon lead of 5 ribbons to folder FE02: 5 driven draw rollers, 5 additional cut-off register controls CutControl C, separate former superstructure (draw unit, Eltex ribbon blocking, driven former roller with centre slitter, motorized longitudinally adjustable bar former with crowned nose and anti-wrinkle roller)

Long Grain Folder FE01

• Type: PFI-5S, system 2:5:5, fully automatic changeover
• Motorized axially adjustable cross perforation
• 2-part knife cylinder, 5-part pin/folding-blade cylinder, 5-part jaw cylinder for the 1st cross fold
• Product deceleration by cam brake ahead of the splitting device, rotary splitting device with displacement cam
• 2 deliveries for cross-fold products (A/B products)
• Magnetic product brakes ahead of the two 3rd-fold units
• 2 second longitudinal fold units (3rd fold), each with separate delivery (A/B products), with merging of the 3rd-fold products to the lower delivery

Short Grain Folder FE02

• Type: PFI-5L, system 3:5:5, fully automatic changeover
• Longitudinal trimming device for head and foot trim at the folder infeed
• Motorized axially adjustable cross perforation
• 3-part knife cylinder, 5-part pin/folding-blade cylinder, 5-part jaw cylinder for the 1st cross fold
• Cylinder stitching unit Tolerans Speedliner, single-part
• Product deceleration by cam brake ahead of the splitting device, rotary splitting device with displacement cam
• 2 deliveries for cross-fold products

Control Station (Leitstand)

• PECOM Basic: AC drive concept, decentralized PLC control and process electronics
• PECOM ConsolSystem: Console System Server, 2 PressConsoles with ColorDesk and colour viewing light, 1 auxiliary desk, 2 FolderScreens
• Interface for GMI ColorQuick density control
• Colour register control CRC-S: circumferential, lateral, overall circumferential register and print position control
• Cut-off register control CutControl C for 11 ribbon leads in total: circumferential and lateral ribbon position control, motorized camera positioning
• Waste reduction function package: start-up sequence, dryer and blanket washer integration
• PECOM Extended: PressManager, PresetManager (ink presetting via PrepressLink, component presetting), PressMonitor (logbook, production report)
• PECOM QuickStart waste reduction package: inking unit conditioning, pre-inking, start/stop sequences, run-up curves, dryer control, blanket wash control, dynamic inking
• PressManager server, 2 additional PressManager workstations, 4 PressStatus licences (intranet portal, up to 10 clients), PECOM PressLink interface
• Large copy counter display: 5-digit LED, 100 mm digit height

Periphery

• Dampening solution unit technotrans delta.d 400 W with intermediate tank system FZT/P 200/4 incl. doser, console link, pH and conductivity display; one intermediate tank with return pump per double printing unit; without alcohol stabilizer
• Dampening solution pre-filter system technotrans hydroflow (ring belt filter)
• Automatic dampening solution cleaning system technotrans spinclean.d auto
• Ink supply system MAN Roland / technotrans systems for 4 double printing units: 4 ink consumption measurements incl. ink filters, ink pipework along the press with colour sequence change, ink level control (2 per double printing unit), automatic B-/C-Stoff switch-over, console integration
• Cooling centre Axima i-cool with integrated inking unit temperature control
• Plate bending machine MAN Roland with external unit (no plate punch)
• Fluid-Box pre-installation system: cooling water supply/return, compressed air pipework for compensators and printing units, integrated cable duct

Technical Details