Consumables
Baldwin System Solutions Deliver Added Value at Gulf Print 2009
Tuesday 07. April 2009 - Baldwin Technology Company, Inc. is exhibiting an enhanced range of equipment, consumable and support solutions to increase productivity and lower operating costs for sheetfed, commercial web, semi-commercial and newspaper printers at Gulf Print 2009. Fluid & Temperature System Solutions Cleaning System Solutions-Cloth & Brush Cleaning Consumables Spray Dampening System Solutions Web Security System Solutions In-line Finishing System Solutions IR Drying & UV Curing System Solutions Service Packages & Support Solutions
Baldwin is using Gulf Print 2009 to unveil a host of industry-leading process automation technologies, which have been designed for use across all graphic arts industrys market segments – sheetfed, commercial web, semi-commercial and newspapers. Baldwin is already a major supplier of equipment to the Middle East, both indirectly via OEM press manufacturers and directly via equipment to end customers (publishing and printing houses) and its global consumables, parts and after-sales service.
The company is a leader in developing and supplying technologies that enhance print quality and press productivity, whilst reducing wastage and environmental impact. Baldwin says it anticipates significant growth in the Middle East market and plans to build upon its recent successes in this region. Its systems for reducing press down-time and costs are particularly attractive to printers and publishers operating in an area where paper prices continue to be high compared with many other parts of the world.
Fluid & Temperature Systems
For 50 years Baldwins fluid and temperature control product range has provided options for all market segments, performance and capacity requirements, including solutions for reducing or eliminating alcohol. These systems are particularly popular amongst sheetfed printers. Fluid and temperature technologies include the fountain solution conditioning systems, BasicLiner, CombiLiner, DailyLiner, Automix, Basic/HighTemp, BalControl and IpaSonic, plus the fountain solution filtration technologies, LongLife-C and Performance filtration.
All of Baldwins filtration solutions are designed to achieve savings on dampening solution additives, alcohol and energy. The Performance filtration system is designed for the sheetfed market and the LongLife-C filtration system for the semi-commercial and newspaper rmarket, the latter is based on a strategic partnership with specialist manufacturer Falk GmbH, Germany. This system removes dirt from the dampening solution while ensuring the additive, alcohol or alcohol substitute percentages remain unchanged.
Fountain Solution and Temperature Control Systems-BasicLiner, CombiLiner, DailyLiner
Baldwins BasicLiner, CombiLiner and DailyLiner units have been specially developed for the sheetfed, commercial web, semi-commercial and newspaper markets, and supply printing units with pre-mixed, circulated, cooled and controlled fountain solution. The state-of-the-art technology incorporated within the units guarantees highly precise mixing, cooling and control. Baldwin offers various types of fluid and temperature units, each with different, accurately staged flow and capacity capabilities to suit various press requirements. DailyLiner meets the demanding requirements of spray dampening systems. The CombiLiner-E unit has a new frequency-controlled drive, which is influenced automatically by ambient temperature and so always operates at its optimum performance. This can result in energy savings of up to 20%, as well as reduced environmental impact.
Filtration Systems for Fountain Solution – Performance and LongLife-C
Long-term use of dampening solution is only possible if paper fibres, coating elements, ink particles, dust and other impurities are continually removed. Effective filtration stabilizes the dampening solution process parameters, increases the solutions useful life and reduces costs. Baldwin provides dampening solution conservation, cleaning and waste disposal solutions for a wide range of press needs, with versions suitable for a variety of budgets.
All Baldwin filtration systems work using bypass flow filters: they draw their supply from the dampening water system reservoir, clean the dampening solution and carry it back into the reservoir. Where a change of filter is necessary, for some cycles with certain types of Baldwin systems, press minders can do this while the press is running. Baldwins LongLife-C system, developed from a strategic partnership with Falk GmbH, Germany, achieves the maximum increase of the active life of the dampening solution in newspaper and semi-commercial printing using spray dampening. This system employs transverse current filtration technology, using special low-maintenance ceramic filters. A by-product of optimal dampening solution cleaning is a concentrated form of residue, which is collected in a tank. Because residues are so low, less effort and cost are involved in waste disposal.
Baldwins filtration systems can be easily retrofitted to existing press lines and provide significant benefits when integrated with a spray dampening system, because the return fountain solution can be cleaned and reused. One UK newspaper, which fitted a LongLife-C system to a 12-unit Goss Colorliner, reports waste water from its spray dampening system being reduced by more than 95%. The company expects significant savings of fount solution additive.
Spray Dampening Systems
Spray Dampening – LithoSpray Maxima and LithoSpray World
Baldwins LithoSpray Maxima unit is the first spray dampening system that has been designed for both heatset (commercial web) and high performance, semi-commercial newspaper printing applications. LithoSpray Maxima incorporates as standard Baldwins maintenance-friendly Constant C air curtain technology and has a range of control and valve speed options.
The LithoSpray Maxima and LithoSpray World systems offer proprietary control algorithms, which make them an ideal partner technology for faster pre-setting of ink and water, resulting in faster press start-up and reduced waste. The valves and nozzles within a spray dampening system have to provide consistent dampening at all times and both LithoSpray Maxima and LithoSpray World ensure high spray frequency with precise water volumes and uniform dampening. The systems are easy to install and maintain.
Air Curtain Technology for Consistent Performance – Constant C
Baldwins unique Constant C technology eliminates the problem of plugged or blocked nozzles on spray dampening systems by providing an air curtain around the nozzle tips, which keeps ink mist and debris away. With this feature, nozzles perform at the same high quality level at all times. Constant C technology can also be supplied with or retrofitted to existing LithoSpray World or LithoSpray Optima spray bars.
Sealing Technology for Unrivalled Reliability – U-59
Baldwins valve and nozzle assemblies now incorporate as standard the use of U-59, a stable sealing material that withstands ink and blanket wash chemistry, thus making it possible to operate the spray dampening system in a closed loop environment with dampening solution recovery. This allows a precision never previously achievable in spray dampening systems, resulting in more effective dampening and less environmental impact.
Cleaning Systems – Cloth & Brush
Dry Cloth or Wet Technology Systems – ImpactFusion-F
Baldwin has developed and optimized several automatic blanket cleaning technologies for the heatset, semi-commercial and high-performance newspaper sectors. These include ImpactFusion-F NP, which offers the flexibility of being used with PREPAC or DryPac. This system offers the substantial advantages of the established ImpactFusion-F CW technology for the commercial web market, including highly effective cleaning of blankets and cylinders, ease of operation, cloth changeover and maintenance plus low wastage. In addition to compact, single cleaning units, the ImpactFusion-F NP system also has dual and multiple units that can clean several cylinders simultaneously.
Rotating Brush Systems – ProTech
ProTech2 NP is Baldwins new brush cleaning system for the newspaper and semi-commercial print sectors. Operational and performance features have been upgraded to meet the latest newspaper and semi-commercial print requirements. A pivoted doctor blade in the cleaning units cleans the brush rollers, and this greatly reduces wash-up times and washing agent consumption. Intervals between maintenance sessions are also significantly increased because the wash unit has the benefit of inbuilt self-cleaning. For the commercial web market, Baldwin offers its well established ProTech CW equipment.
Clean-by-Web Systems – TowerClean
TowerClean is a cost-effective, automatic blanket cleaning system for single width newspaper and semi-commercial presses that automates cleaning, increases press productivity and improves print quality. TowerClean enables the blanket to be cleaned by contact with the moving web once the small profile applicator has applied a low-VOC solvent to the paper. As the web reaches the blanket the brush unit, which is frequently installed only on the first-down blanket, is activated. This removes the lint and ink from the blanket surface. In addition, the TowerClean process has a positive cleaning effect on the guide rollers. TowerClean can easily be retrofitted to existing presses where newspapers are looking to eliminate manual blanket cleaning. Waste copies are low with this system. Depending upon the build-up on the blankets and press running speed, waste copies are normally from 80 to 250.
Web Cleaning Systems – JetStream
Technology that enables debris to be removed from the web before it enters the press is rapidly being taken up by the newspaper and semi-commercial industry. Baldwins JetStream system is a revolutionary approach to this challenge and results in improved print quality, productivity and profitability. Some newspaper printers operating JetStream report being able to print millions of impressions before a blanket clean is required on the press. As well as improved print quality, removing dust from the atmosphere results in a much better working environment for staff. Combining JetStream with one of Baldwins blanket cleaning technologies allows the printer to produce long runs of high quality from the first to the last print. Baldwin offers, on all of its cleaning systems, a full or partial integration into the central control console, as well as stand-alone solutions for both new installations and retrofits, guaranteeing easy operation.
High-Performance, Cost-Effective Press Consumables-PREPAC, DryPac and JumboDry
In line with its manufacturing strategy, Baldwin offers a unique range of cleaning cloths with high absorbency and durability for its automatic cloth cleaning systems. Baldwin supplies dry cloths as either custom-made, ready-to-use DryPac rolls or, for users who prefer to wind their own rolls, as JumboDry rolls. The cost effective DryPac E and JumboDry E options are designed for normal cleaning requirements, while DryPac Plus and JumboDry Plus are suitable for the most demanding jobs. There is also a cloth version with an extremely high resistance to linting.
The special PREPAC products are read-to-use, vacuum-packed, cleaning cloths containing a precise amount of low-VOC cleaning agent. Baldwin offers three versions of PREPAC, each designed for different performance requirements and budgets. The range includes the inexpensive PREPAC E for moderate requirements, PREPAC Plus with more cleaning power and the premium quality PREPAC X-treme, designed and customized for extremely high performance. All PREPAC options are approved by Fogra.
Web Security Systems
Press Protection System – WebCatcher
The need to prevent press damage caused by web breaks has become increasingly relevant within the newspaper and semi-commercial markets and Baldwins systems have been installed at a variety of customer sites, many in high-performance, demanding situations. In the area of web protection, Baldwin offers reliable web separation and clamping devices under the product name ProTect and the new WebCatcher S14 as well as the WebCatcher S18 for use in the commercial web, semi-commercial and newspaper area. The new WebCatcher S14 will prevent press damage from a web break at speeds of up to 13 m/s and the WebCatcher S18 for web speeds of up to 18 m/s. Customer options for the WebCatcher series include the stripe wrap-up recognition system DSWP and the automatically adjustable airknife Triple A.
In-line-Finishing Systems
Silicone Application System – WebSiliconer
Baldwins in-line finishing systems for semi-commercial and commercial web applications include the newly developed WebSiliconer, which leads the industry in terms of silicon application technology for web offset presses. Baldwins WebSiliconer applies an even amount of silicon across both sides of the web, up to web widths of 2,860 mm and at speeds of up to 18 m/s. The silicon/water mix can be adjusted extremely accurately in 0.5 per cent steps. Pneumatic cylinders engage and disengage the rollers with the web and a web scraper prevents accidental contact with the paper when the rollers are disengaged. The unit is highly efficient and ensures the minimum amount of silicon is used. It provides excellent access and requires little maintenance.
In-line Gluing System – WebTack
Baldwins WebTack system has been developed by the Swiss gluing technology specialist Robatech AG, for the application of dispersion glue and softening of the paper web. WebTack, marketed globally by Baldwin exclusively for the printing industry, applies fluids via special carbide ducts in contact with the web. The applicator heads are seated on cross beams, either singly or in pairs. Predefined and individually programmable glue patterns enable a fast, waste-saving make-ready and give the option of remote motorized adjustment of the applicator heads both horizontally (laterally) and vertically (towards the web). These settings can be made via corresponding links to either the press control station or the touch screen panel on the WebTack console.
In addition to straightforward newspaper applications, WebTack can be utilized in a wide range of semi-commercial applications in order to produce a variety of products such as magazine supplements, advertising inserts or special publications, including work that is usually stitched on the press. The system is quick to make-ready, requires very little maintenance and is extremely efficient in use, providing a highly accurate edge glue line with clean gaps. The bag in box glue supply is environmentally friendly and helps to ensure low adhesive consumption.
IR Drying & UV Curing Systems
Drying Systems – InfraOrange, Compact, Graphiset 1 – 4 and FlexoSet
Baldwin is a major supplier of drying systems and this includes the InfraOrange, Compact, GraphiSet 1 – 4 and FlexoSet products, which provide a comprehensive range of drying options for sheetfed, semi-commercial and newspaper presses. The company has been working closely with Nordson UV and has recently signed a Private Label Supplier agreement that allows it to rebrand Nordson UV equipment in certain countries and offer customers UV, UV/IR combination and IR drying systems. In the Middle East the two companies have an informal relationship that enables printers to more easily acquire the curing and drying facilities that best suit their needs.
Service Packages & Support Solutions
In todays demanding market, printers have to achieve maximum productivity and reliability from equipment. Baldwin offers customers a level of support through its highly efficient global service organisation to help customers obtain these goals. Individually tailored service packages can incorporate retrofits and system optimisation, after-sales support, spare parts etc. Preventive measures can be added into the package. Baldwin offers special retrofit upgrades so that customers can maintain their systems at optimum efficiency, while the companys consulting and training services ensures users obtain the maximum benefits from their Baldwin equipment.