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9 Web Offset Automation Features You Must Know About

DAMPENING SYSTEM

1.Cloth Dampening :-

It is the conventional dampening system, in which water pan roller transfers the water to sock roller, which in turn transfers to chrome roller and then to damp forme roller and then to plate. Comprising of one form roller, a chrome-plated oscillating drum, a transfer roller and a motor-driven fountain roller, which can be regulated independently of press speed for precise control, continuous-feed dampening system is reliable and easy to use.

This system gives good printing results, however, if the production run is longer say above 50,000 copies per shift then quality of sock/cloth becomes very important as cloth has a tendancy to get heat up with continous use.

2.Brush Dampening :-

Another system is brush dampening in which instead of sock roller, spiral brush roller is used. This brush roller is connected with independent fixed speed motor. Water pan roller transfers water to spiral brush, which instead of transferring full water, transfers droplets of water to chrome roller at high rpm. These sprinkles of water droplets create a firm water layer on chrome roller. It is an ideal dampening system for long production runs and has very little maintenance issues.

3.Spray Dampening :-

Spray Dampening System is the latest state-of-the-art dampening system. It increase efficiency and print quality, reduced start-up-waste, and savings in water and ink.The system has patented valves allowing a higher spraying cycle
frequency, delivery of precise water volumes, and uniform dampening of the plate cylinder.

Spray bars are installed directly at chrome roller and has high pressure water input. As the name suggests these bars spray water directly to chrome roller in form of mist. Since, it is installed higher in dampening train it has profound effect in time and precision of water reaching to plate cylinder. With this system there is no water pan roller or transfer roller. This system is fully programmable and comes with PLC control

REGISTRATION SYSTEM

1.Manual registration :-

It is the most basic and inexpensive method for registration control and comes as a standard accessory. Lateral and circumferential register control is given on machine itself with easy to use attributes. With handles, operator use physical force to turn easy to use handles to adjust registration. Each printing unit has its own registration adjusting handles

2.Motorized Registration :-

An alternative system is motorized register system, wherein, an operator can adjust registration laterally and circumferentially from a remote desk. In this system, each colour is fitted with independent AC syncronous motors with end limit control. Each motor has its control on operator desk and can be easily operated remotely.

This system allows a single operator to have full control on entire registration system of the press. Manpower requirement goes down significantly as now single man can take care of all printing units registration.

This system offers greater control over the press in comparison to manual system and less manpower requirement. With motorized system, press comes with enclosure doors. This system is ideal in a situation where there are multiple printing units, print waste is absolute critical and quality manpower is scarce.

3.Auto registration system :-

Automatic registration control system is a proven technology. It is a close loop system equipped with intelligent camera that continuously monitors and controls any deviation in registration. It comes with an easy to use touch screen user interface. The major advantage of this system is that it leads to huge saving by reducing wastage considerably which takes place during start up of the press. Since it is close loop system, even operator intervention is not required whenever there is a deviation in registration. Camera on top of printing units detects it automatically and does the correction immediately. It is extremely responsive and provide much needed consistency and repeatability in print.

It is the most advanced form of automation in registration system, which itself takes up 80% of operators’ time during production. This system makes the job easier and production smoother.

INKING SYSTEM

1.Conventional system :-

The inking system consists of a swing-down ink fountain which allows easy cleaning. 24 keys/ lever across the width of the ink fountain roller control the ink feed. The ink override control mechanism on the ink fountain roller ensures quick distribution of the ink all along the surface of the roller during printing runs and also easy cleaning of the ink fountain.

2.Remote inking :-

n this advanced system, all ink zones are pre set based on CIP3/CIP4/TIFF/PDF file that you get from your CtP. Operator does not have to adjust ink keys manually. Each 24 keysis motorized and can be controlled from the desk. With help of this system first copy that you print is already ink tuned and corrected. You have the option to increase or decrease ink level in a particular area based on actual print that you are getting but most of the ink setting job is done automatically. This system can be easily retrofitted even in the existing press.

ON/OFF CONTROLS

1.Pneumatic on/off controls :-

This is an easy to use system where all on/off functions of the machine such as impression, ink and dampening are fitted with pneumatic cylinders. These cylinders operate with air and can be controlled from remote desk. This system allows operator to switch on all systems in one shot thereby decreasing print waste and saving operator effort to reach out to each printing unit and switching on/off manually.

You will need dry compressed air supply for this system to function. Pneumatic system is a proven system with the record of saving print wastage and time.