Manroland Lithoman IV 64pp

Equipment

Key Data

• Cutoff: 620mm (24.41")
• Width: 1905mm (75")
• 64 pages
• Contiweb Reel Splicer
• 4 colors
• Contiweb Dryer
• Folder: Cross fold, Parallel fold, Delta fold, Tabloid Two second longitudinal folds), with collect production
• Machine in excellent condition
• Located in Germany, can be inspected in Production

Reel Splicer

• Contiweb FD 18 automatic reel changer (flying paster) with automatic reel logistics / infeed
• Prepared for paper reels up to 60″ diameter
• Integrated draw unit
• Core drive
• 3 parking positions for splice-prepared reels
• Fixed clamping cones
• Ethernet interface
• PECOM part-integration
• Reel-door shielding for 18 m/s
• Web-up device
• Web data with house connection and reel ticket for transfer of reel data to the printnet Monitor server

Paper Infeed Unit

• manroland automatic web lead-in device, from the reel changer through to the cutting unit ahead of the offset bars, at a lead-in speed of approx. 50 m/min
• Lead-in runs on the drive side (SII), keeping the operator side (SI) clear
• Magnetic lead-in tongue for fast web hanging with minimal adhesive-tape consumption
• Support for the web-sever device and the spreader roller, positioned ahead of the first double printing unit
• Web guide rollers in CFRP design (concave, grooved)

Printing Units

• 4 double printing units (4/4 = 8 colours), vertical four-cylinder blanket-to-blanket design in box-type construction
• Plate cylinders with clamping spindles for one full-width plate (plate thickness 0.4 mm; undercut 0.33 mm for production without underlays)
• Circumferential register adjustment ±3 mm, side register ±2 mm, plate diagonal adjustment ±0.285 mm, all adjustable on the run
• Reinforced film inking units, each with 4 form rollers (two centre rollers oscillating), 3 oscillating steel distributor rollers with ceramic coating and temperature control, adjustable bridge roller for ink-flow control, film roller, ductor roller, large-capacity ink fountain with lamellar ink blade
• Hydromix dampening units, integrated film/ink (alcohol) dampening units with selectable run-up curve, each with one ceramic-coated dampening distributor roller and a round dampening ductor with moisture-carrying cover, remote-controlled from the console
• APL automatic plate-loading device, operable per double printing unit [top/bottom] or for all four units from the control desk
• Anti-emulsification device per double printing unit, with doctor bars and complete blade set for production with part-width webs
• AutoCycle for cyclical adjustment of side and circumferential registers
• Roller in-/out lifting device (manroland)
• Baldwin automatic ink-roller wash unit, complete for all double printing units (spray bars, wash doctor with tray, microprocessor control)
• Baldwin Impact Fusion F blanket-wash unit for 4 double printing units (CleanLiner supply cabinet, wash beam with pneumatic cloth feed, DryPac pre-fabricated wash cloths with water/detergent dosing, including second set of DryPac cloth rolls and rewinding stand)
• Image-register units: one ahead of printing unit 1 (5 motorised image registers), and three units ahead of printing units 2–4 (each with 5 image registers combined with 5 blow-air nozzles on the web underside), pneumatically swivelling
• Photoelectric web-break safety detectors
• Inline-Plattenbiegemaschine (fully automatic inline plate-bending machine) with external feed

Ink & Dampening Supply

• Ink supply system (manroland / technotrans systems GmbH) for 4 double printing units with full PECOM integration: four ink-consumption measurements, ink pipelines along the press with ink-sequence change, two ink-level controls per double printing unit, automatic B-/C-fluid switchover
• technotrans delta.d 450 W dampening solution unit with pre-filter intermediate-tank system FZT/P 200/4, including digidos.p 250 RC doser for two dampening additives, console connection, pH and conductivity display; chiller, intermediate-tank system with return pump per double printing unit, fixed switchable reserve pump
• Baldwin spinclean.d auto automatic dampening-solution cleaning system (centrifugal separator, bypass operation to the dampening-solution tank)

Register Control

• manroland InlineRegister Control PU colour-register control, regulating up to 5/5 colours, with motorised camera positioning, integrated in the PECOM ConsoleSystem; cameras placed in a separate support ahead of the dryer infeed; single-web with 2 colour cameras for 2–8 colours; automatic mark search; individual-unit activation/deactivation; mark change during production
• QuadTech Color Control System on ICON (SpectralCam) closed-loop solid-ink-density control with reporting (CCS-IF-WR, Instrument Flight); measures density, contrast, dot gain and trapping in process; main computer, free-standing scanner stand with motorised reading heads per web side, colour-strip pre-press package, Optiguard per reading head

Dryer

• Contiweb Ecoset 173 hot-air drying unit, single-web, approx. 17.3 m drying length, with integrated thermal exhaust-air cleaning and chill-roll zone
• Integrated afterburner with solvent combustion; energy from solvent combustion reused in the heating process
• Two temperature zones (heat-up and drying); patented "Crossjet" air nozzles; web-temperature control via infrared camera; reingas values per TA-Luft, EN 1539, NFPA 86 and VDI; door sensors; remote diagnosis via VPN
• Chill-roll section: 9 small-diameter chill rolls (cross- or single-grooved, concave); the fourth roll is the only driven roll; re-moistening with silicone applicator ahead of the first and second chill rolls (silicone and water quantities regulated separately onto the web); Contiweb web-edge control system and web-break detector; web-tension and web-temperature measurement after the chill rolls

Former / Folder Superstructure

• Single-web former superstructure consisting of an angle-bar section and a former section for a folder arranged parallel to the machine's longitudinal axis
• One pair of side frames with gallery elements; paper guide rollers (CFRP uncoated, concave, grooved; thereafter aluminium or chrome-plated steel per inertia requirement)
• Cutting unit with 4 slitting knives, dividing the web into 5 ribbons, motorised and pre-settable
• Spreader roller for the full-width web at the cutting unit
• Driven draw roller with nip roller
• 5 angle bars for 90° turning of the ribbons onto the main former, each air-cushioned with part-air shut-off, laterally adjustable from the console
• 5 draw-roller pairs (one per ribbon) after the angle bars, individually driven
• 5 regulating devices with electromotive adjustment for cut-off register
• 5 photoelectric cut-off register controls (manroland Inline Cutoff Control), one per ribbon
• 5 web-tension measuring rollers, one per ribbon
• manroland-Weko WFG 1.4 strand-siliconising unit, single-sided silicone application to the ribbon on the main former (ribbon underside)
• Planatol Combijet 9NET combined longitudinal-gluing and folding-aid device, with 7 application heads, including interface for PECOM integration (operation from console and folder panel), motorised height adjustment via on-site control panel
• Driven draw-in device with nip roller ahead of the former roller
• Driven former roller with tension rollers and cutting device on former centre
• Perforating device beneath the former, for bottom-to-top perforation
• Former (rod-type, former position in strand-run direction) for the 1st longitudinal fold, motorised longitudinal traverse and pre-settable

Folding Machine

• Folder PFC-252 (System 2:5:5) with intermediate section and two second longitudinal folds (3rd fold) for collect production or double production with product combination
• Complete cross-fold group for DIN A3 production and A4 production folded over the head
• 1 set of side frames; 1 pair of former-infeed rollers
• Driven draw roller with infinitely variable lead and pneumatically applied nip rolls; electronic strike-down and reject device
• Cross-perforation for the 1st cross-fold (driven, motorised circumferential regulation on the run, adjustable perforating intensity)
• Longitudinal perforating / scoring device with motorised side-register adjustment, motorised knife on/off and suction nozzles
• Folding-cylinder group (own-motor driven): cutting-knife cylinder (2-section, two cutting-knife bars with offset cut for collect production); pin and folding-knife cylinder (5-section, with five pin and folding-knife systems); folding-jaw cylinder (5-section, 5 jaw systems with central jaw-gap setting); over-fold device for the first cross-fold with motorised on-run setting [±12 mm]
• Second cross-fold device (2nd cross-fold cylinder) for double parallel folds and delta folds: gripper / folding-knife cylinder, 2nd folding-jaw system, swivel-out unit, plus one delivery for the cross-fold products
• Product-guiding system at the folding cylinders; sheet-slowdown ahead of the splitting unit
• Splitting device (own-motor driven, rotating splitting cam)
• Belt-conveyor system (own-motor driven) to the two 3rd-fold devices and to the delivery
• 2 × 3rd-fold devices, each consisting of a folding drum (own-motor driven, rotating folding knife, electronically controlled), folding table (pneumatic sheet stops, motorised to fold centre), electromagnetic sheet brake, hardened-surface folding rollers
• Product combination: production of two second longitudinal folds onto the lower A4 delivery
• 2 delivery systems for separate A4 production, each with a 16-blade fan wheel (oval blade form, integrated timing wheel, motorised circumferential adjustment on the run) and a belt delivery with separate drive (products delivered closed-edge first)
• Conversion device for automatic changeover between the various production modes, button-operated from the folder panel
• Oil-circulation and central grease lubrication systems; protective and safety equipment

Control Station

• PECOM Basic electronics concept with AC drive technology, decentralised PLC control and process electronics
• PECOM ConsoleSystem with two PressConsoles and one auxiliary desk, arranged parallel to the press
• Two ColorDesk units with two colour-proofing lamps for operator inspection of the printed sheet
• PECOM Autocycle functionality; PECOM PressInterfaces for sub-system integration; PECOM-PressLink connection interface
• AutoJobChange — sequenced production change (product load, ink/component presetting, APL, run-up-ramp switchover, QuickStart, QuickStop, product unload) for frequent subject changes
• PECOM QuickStart make-ready-waste reduction package (ink-train conditioning, pre-inking, on/off sequences, run-up curves, dryer control, blanket-wash influence, dynamic inking)
• WasteGateControl waste-gate control for optimised, automated waste ejection
• PECOM ClosedLoop control systems: InlineCutoff Control and CutoffControl dynamic (cut-register control via additional measuring heads, tolerance band down to under 3/10 mm in continuous running)

Technical Details