Consumables
Baldwin Protech2 NP Brush Cleaning Technology Results In Major Cost Savings
Wednesday 29. October 2008 - The Baldwin ProTech2 NP system - a more advanced version of the manufacturer's successful brush cleaning technology for blanket and impression cylinders in newspaper and semi-commercial printing - has recently been launched in the market.
The new system meets today’s requirements for quality, efficiency and economy in automatic cleaning of newspaper and semi-commercial presses, a claim recently justified by a nine-month field test at SV-Druckzentrum in Munich, Germany. The results of the trial are impressive: compared to the previous generation of cleaning technology, Baldwins ProTech2 NP led to a dramatic reduction in cleaning agent consumption, shorter cleaning times, significantly longer intervals between maintenance and a range of other benefits to the printer.
Baldwin (then Oxy-Dry) worked extensively several years ago with SV-Druckzentrum on the development of the first brush cleaning system for newspaper presses, as well as on a cleaning system for guide rollers. It therefore comes as no surprise to learn that all the presses at this Bavarian printing house – six manroland Colorman newspaper presses, each comprising three towers with ten-cylinder printing units, and four KBA Commander four-high units – are equipped with Baldwin cleaning technology. Baldwins LithoSpray Optima spray dampening systems are also fitted to all of the presses.
The company benefits from Baldwin’s system supplier concept: the decision to purchase several products from the same source reduces the number of contacts for installation, maintenance and service. The resulting concentration of system responsibility saves users considerable time and prevents inefficiencies and misunderstandings in the event of problems or service.
Centre for ambitious newspaper printing quality
SV-Druckzentrum, the most important printer in the Mediengruppe Süddeutscher Verlag group, produces newspapers and advertising journals. Its flagship product is the prestigious national Süddeutsche Zeitung. The portfolio also includes part editions of Bild, Bild am Sonntag, Die Welt, and Welt Kompakt as well as various advertising journals. Since 2002, following the completion of the sixth Colorman installation, the company has been able to print entirely in full colour. SV-Druckzentrum has long been a committed advocate of standardized newspaper printing in accordance with ISO 12647-3, and is also certified in line with this standard.
“By standardizing our workflows, not only do we comply with advertiser demands for repeatable colour and print quality, but we generally encounter fewer problems in daily production,” says Robert Heitzer, head of the printing department.
The company has made a name for itself with exclusive newspaper advert specials and enjoys an excellent reputation throughout the industry. Special multi-page adverts and supplements are printed on glossy uncoated, coated, or transparent papers, processed with burst-open fragrances or with fluorescent or metallic colours, and produced in custom page formats such as flying pages or half-covers.
“We see it as our mission to create an innovative newspaper environment for advertisers, says Uwe Seifert, the printing department’s deputy head. “Our goal is to get the most out of the coldset press and the available consumables without additional investment for drying.”
Press automation equipment such as automatic blanket cleaning systems must not only contribute to the consistently high print quality stipulated by users, but also reduce make-ready times and waste. Robert Heitzer explains the decision to invest in brush cleaning technology taken all those years ago. “It is a top priority for us not to need any materials other than cleaning agent and water, and to be able to rely on the cleaning system at all times.”
Four blanket cleaning units work according to the one-for-two principle (one brush simultaneously cleans two blankets) in each of the 18 Colorman towers. In addition, thirty-two one-for-one units are installed in the KBA Commander towers. Heitzer adds that the blankets are cleaned after every long run or as and when necessary, usually after 100,000 to 150,000 impressions.
Team play between system developers and newspaper printers
SV-Druckzentrum’s satisfaction with its existing Baldwin cleaning technology and the immense trust that has grown up over the years between the two partners meant that the company had no hesitation in agreeing to take part in the ProTech2 NP trial. In October 2007, one of the new brush cleaning modules, which successively cleans two blankets according to the pivot-for-two principle, was installed in a printing unit on the Colorman press. This printing line, which is designed for a web width of 1,600 mm, allowed a direct comparison between the existing cleaning equipment and the new generation.
The aim was to optimize the cleaning performance, time and intervals of the ProTech2 NP system as well as its ease of use and consumption of cleaning agent. SV-Druckzentrum uses a universal cleaning agent for blankets, guide rollers and inking rollers. During the trial the company continuously documented the cleaning results along with any suggestions for improvements. Baldwin’s R&D experts paid regular visits to the site to implement appropriate optimization measures.
30% faster, 50% less cleaning agent, significantly longer maintenance intervals
It was possible to optimize the system to the extent that the ProTech2 NP system achieves the desired results with around 30% faster cleaning and 50% lower consumption of cleaning agent. The main reasons for this are the constructive dialogue between the two project partners and the resulting technological advances of the ProTech2 NP cleaning unit. One new feature, for example, is the application of cleaning agent to the blanket cylinder by the brush roller rotating in the same direction. The brush direction is then automatically switched to counter rotating, so that the ink and paper fibre mixture that has built up is efficiently removed from the blankets.
The pivot-for-two principle has the advantage that only one brush unit is required for two blankets. Another innovation is the swivelling scraper, which only contacts the brush roller when it actually needs to be cleaned. This integrated self-cleaning technique prevents unnecessary loss of cleaning agent that has only just been applied to the brush. The dirty fluid that is scraped off is collected in a defined drip area in the ProTech2 NP cleaning unit and automatically rinsed out with cold water after each self-cleaning cycle.
When it comes to operation and handling, the Munich newspaper printer willingly testifies to the new Baldwin ProTech2 NP system’s genuine advantages. The brush roller is lighter and can be individually removed from the installed unit easily for inspection or maintenance. Adjusting the cleaning units to the blanket cylinders is also far simpler than in the past. A further point in its favour is that the drip pan for the discharged dirty fluid now only has to be cleaned once every three to four weeks instead of every two.
The ProTech2 NP trial at SV-Druckzentrum ran for nine months without a single hitch. Robert Heitzer, who has been with the company since 1996, sums up his experience as follows: “We learned in the course of daily production that an even more efficient and economical way exists to clean our blanket and impression cylinders. This lesson will undoubtedly prove useful for future investment decisions. Without question, this is the kind of project that deserves to be supported by anyone keen to promote technological progress in our industry. After all, we are the ultimate beneficiaries.”